Using a strap duplicator, locate and match drill holes in side panels to match the tunnel cover.
Remove console and tunnel cover.
Cleco console to tunnel cover and complete match drilling holes.
I deecided to split the tunnel cover in three pieces to facilitate ease of future tunnel inspections. The first section is about 6 1/4" long and will likely remain permanently installed. The 4 screws that will secure this piece are difficult to access. The second section continues to just aft of the fuel selector. This will allow tunnel inspection without removing the lower console, throttle quadrant, and fuel valve. The third section is what remains.
Doubler flanges were fabricated from 040 sheet. Rivet paterns were marked and drilled in the doubler, then the tunnel cover was match drilled for the doublers. The drilling occurred PRIOR tocutting the tunnel cover so as to maintain the correct mounting hole spacing.
Once all of the rivet and screw pilot holes were match drilled in the cover, it was cut on the bandsaw and filed smooth.
