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Christopher's Web Site
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Date: 2-3-2016
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Number of Hours: 2.00
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Manual Reference:
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Brief Description: Control Rod Clearance Issue Resolution
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I thought of several ways that I could attempt to cut out the holes with the kick panel in place such as hacksaw, drilling, metal sheers, etc, but nothing worked without the clear assurance that I wouldn’t damage the panel. I tried drilling, but realized that the heat from the larger bits would heat up the metal and would likely warp the panel as it did on the one I just replaced. Everything else I tried was also abusing the panel and bending the edges. Taking the panel off was going to be like starting over, so that really wasn’t on the table.
My buddy Tom suggested using a hydraulic hole cutting punch set that basically works like the system that I used to cut out the instrument panel holes. This felt like the best idea, but at the end of the day, I just didn’t have the clearance I needed for the tools required.
Finally, I was able to “carve out” the hole using a pneumatic nibbler. I made some crude cuts that took the bulk of the metal off the panel, then I carefully and gradually nibbled away until I was as close to the line as I could get without risking an overrun, then filed the rest of the way with a hand file. This was very delicate work with a pretty violent air tool, but it worked and I think anyone would be pleased with the results.
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Before modification
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Pilot Side
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Co-pilot side
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