Sand and smooth switch panel using permagrit tools and s/p.
Fabricate switch panel face from 040 2024 aluminum sheet. I decided to fabricate two panels at the same time so as to have a pattern and a spqare blank. Panels were cut, filed, smoothed and drilled as a pair.
Panels were then separated and deburred and edges were further smoothed.
Console was matched drilled to one of the panel faces using #40 drill, cleco as drilled.
Panel was then checked for fit while clecoed to the console. Minor adjustment were marked.
Panels clecoed together and fit was adjusted.
Cleco one panel to console, verify fit.
Apply a skim coat of epoxy, micro, cabo to console to fill pin holes.
