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Bobs Ten
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Date:  3-30-2018
Number of Hours:  5.40
Manual Reference:  
Brief Description:  Install Aerosport Panel

1242 - 1436 1554 - 1906 2030 - 2048

Today was spent creating access in the subpanel for the avionics. I am planning on keeping the 650 low on the panel which predicated a roughly 4" x 7" hole centered beneath the center rib. Using several other examples, I decided to make a larger avionics access hole in the subpanel.

The layout was done previously. Today I cut the opening. All corners were drilled to 5/8" to form a radius. The straight lines were then cut with a body saw. This method is typically imprecise, so all edges were straightened, deburred, and smoothed using a variety of files.

I decided to use 2024T3 063 angle for reinforcement. The top angle was 1" x 1". A rivet pattern was set up and drilled with a #40 drill. This angle was then clamped in position and the subpanel was match drilled using a #30 drill, Care was taken to ensure the vertical reinforcement angles would share a common hole.

The mid angle was 3/4" x 3/4". It was placed as high on the subpanel as the center rib would allow. It was clamped and match drilled to the subpanel.

The vertical angles were 3/4" x 3/4". Again, these wer clamped in position and match drilled to the subpanel and horizontal angles.

All pieces were then removed, deburred and smoothed.

All pieces were then clecoed in place for riveting. I was able to squeeze all but one rivet, which was directly below the center rib. An LP4 rivet was used in that location, all others were AN470-4 solid rivets.

The subpanel, now supported by the 063 overlapping angles, is very rigid.
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