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Bills RV-7 Build Site
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Date:  6-3-2015
Number of Hours:  6.50
Manual Reference:  
Brief Description:  Panel cut-outs

Completed cut outs for right panel. 2 instrument holes were cut using fly wheel cutter, then bolt holes were drilled using jig as a guide. Altimeter and Hobbs meter temporarily installed and panel screwed to frame.

Laid out left panel. There is a lot on this one and it took about 3 hours to get the lay out done. Once layout was done, 1/8" holes were drilled as needed, then enlarged to 1/2 as appropriate for cutting. Rectangular cut outs were then roughed in using a jigsaw. The instrument hole for the g-meter was cut. This was the 4th hole for the flywheel cutter and it took a full 25 minutes of cutting to cut through. The first hole took about 10 minutes, so I guess the cutting blade is shot. Hole for ignition switch enlarged to 7/8". Use file to square up the retangular holes, more filing is needed to get them to final size.

I did not cut the large opening for the EFIS as I want to get all the other holes finished wheile the panel is still very rigid.
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Instrument hole jig

Instrument hole jig

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Left panel laid out

Left panel laid out

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Holes cut (except EFIS)

Holes cut (except EFIS)

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