Since there wasn't room in the panel for the G-5 backup EFIS, I am going to mount it to the top of the glare shield. This requires a case, which I haven't been able to find. So I am designing and building a case myself.
Spent about an hour doing a preliminary design on paper. Decided with my available tools and inability to TIG weld, that I would make the case frame out of aluminum angle riveted together with an aluminum sheet metal cover that will also provide a small glare shield for the G-5.
Started cutting the angle using the band saw and then fine tuning the cuts with the Scotch Brite wheel in the grinder, but wasn't happy with the time required nor the results. After thinking more about it, I purchased a Dewalt 96 tooth, 12 inch carbide blade for my chop saw that is rated for non-ferrous metal cutting. This then allowed me to quickly cut 8 angle pieces all the same by using a stop to set the cutting length. This worked very well.
Drilled 2 #40 rivet holes in each end of half the angles using the drill press, then clamped one undrilled angle to one drilled angle at right angles by clamping to the tri-square and drilled through the holes to match drill the other angles. Counter sunk and riveted the angles together with AN4 rivets. This gave me the two ends of the case.
Cut .063" sheet aluminum to fit between the 2 upright angles to form the front and rear "panels" that will close up the case and that the G-5 will mount through. Used the chop saw to cut these as well.
