Tom, my PA brother has provided me with a big square blank of aluminum sheeting with my configuration of instruments laser cut. This is a huge help since it is really easy to screw up these holes when you are removing so much material. I just need to be really careful cutting this to shape because I only get one shot at it.
I laid out the shape of the cut using the sheet metal blank that I made earlier for the pod. I drew lines on all of the edges so I could center the panel exactly where it needed to clear the angle backing. I had to spend a ton of time using a jigsaw to rough cut the general shape, and then used a hand file to work it to the irregular shape of the instrument pod. It’s not there yet, but I’m getting closer.
Once this is fitted for the pod, I will debur the rest of the internal edges and then dry set the instruments and begin to make brackets for the Garmin 696. In addition, I will need to modify one of the port side brackets to clear the radio mounting. Once I’m sure everything fits well, I will apply 3 coats of wrinkle paint and cook it in the kitchen oven at 200 degrees for an hour as required to complete the curing process.
