As ridiculous as this may seem, seat pans for storage are a critical path item towards my airworthiness inspection. I’m required to have my POH and weight and balance onboard at all times, and I also need to have the trays in the ship for the weighing of the aircraft and determination of center of gravity. They will be super light, but I still need to have everything accounted for.
These are actually very complicated boxes because there are so many bends and spaces to account for. In addition, the left and right are completely different as each area allows for different amounts of useable space.
I first made them out of cardboard, and then moved into a thin aluminum flashing material. It is very easy to overstress the bends, so it took some time. I decided to simply pop rivet most of this to keep the stress from the material.
I finished them with an etching primer and truck bed liner spray paint. You can see that I made a compartment for a spare headset on the passenger side.
