Heat treatable aluminium alloys AA2014 create residual stresses after solution treatment. These residual stresses are then decreased by stretched stress relieving, which is followed by artificial ageing for AA2014-T651. These residual stresses are not entirely removed during stretched stress relieving, and the remaining residual stresses are redistributed in thin wall components, causing distortion in the finished product. If a significant amount of material needs to be removed from the blanks to create thin wall components by rough machining, ageing heat treatment, and finishing machining procedures are often performed. Blanks of AA2014-T651 underwent ageing heat treatment using an experimental temperature and soaking duration. The slitting strain gauge method was used to quantify residual stresses and the proportionate residual stresses and accompanying mechanical characteristics were then included using a correction factor for modelling deformation into a FEA study. Experimented using electrical discharge machining (EDM) to remove material to create thin wall pieces, and then deformation was measured to confirm the results. The analysis’s findings found that residual stresses and deformation are not significantly reduced. For AA2014-T651, analysis of residual stresses is helpful in determining the impact of the reheating process at ageing heat treatment temperatures.