I removed the left bracket from the instrument panel and traced a reference line on the backside of the panel. This should let me track the amount of material I remove from the edge. In order to keep the instruments clean of metal dust, I placed and taped brown paper on the front and back side of the panel. I used files on the left top edge of the instrument panel and filed down approximately 1/32" off the edge, in order to allow the top skin to match up to the fuselage holes. I used the die grinder to smooth the edges. I replaced the top skin in place and found that the skin now lines up with the holes. I drilled the panel to the outboard ribs, up to #12 bit size. I noticed that the center hole thru the panel does not line up with the rib, which already has a nutplate riveted in place. This will need additional work.
Using a straight-edge, I ran a straight line on the glareshield and then used a file to straighten out the center section of the edge. This will give me approximately 1 7/8" overhang on the glareshield over the panel.
Edge of instrument panel masked off after filing
Instrument panel edge ready for filing and priming
