>After a nerve racked morning with a fly cutter I have determined that I am >probably not going the be able to cut the instrument holes. Another option >is a Greenlee punch but those are quite expensive unless someone has one to >loan. With all that said I am thinking that I want to mark up a piece of >.125 aluminum sheet and send it off to someone to laser cut. Any >suggestion on who could do that for me?
Thanks Craig +++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++ I used a fly cutter for the one 3-1/8 hole for the Dynon D10A; small hole saws for the three little gauges; twist drills for the switches and screws. My panel is the stock RR forward deck/instrument panel. I used a .040" aluminum sheet backing up the fiber glass for a ground and EMI shield. All round holes were cut on the drill press. Use a 2x6 to backup the fly cutter and hole saw, and do clamp everything down firmly. Rectangular holes were cut with a Dremel tool fitted with rotary zip saw bits and a router adapter ($8 at Lowe's). Yes, they make bits for aluminum, something like $6 at Lowe's. That was my specific out of pocket cost to cut the panel. To cut a straight line with the Dremel, clamp an aluminum angle or straight board to the panel offset from the cut line for the router base. Granted, my cuts are not CNC precise, but it only cost $6 for two bits plus my time. Pays your money and takes your choice. Sid Wood Tri-gear KR-2 N6242 Mechanicsville, MD, USA smw...@md.metrocast.net
