Brief Description: Marking and drilling holes in the foil.
Yesterday I drilled the rivet holes, so today I taped the foil back onto the FW, and then from aft of the FW I marked all the rivet holes and equipment holes with the Sharpie pen. I removed the foil and laid it out on a piece of plywood covered with heavy paper. I then checked the drawings to be sure I had the correct size of all the holes before trying to drill.
After some experimentation, I used the Dremel tools and stones to make the holes. The stones made a lot of smoke when it pierced the foil into the plywood, but the holes were smooth with no ragged edges. The large holes were cut out using Charlotte's finger nail scissors after piercing with a utility knife. I did make a few of the rivet holes too large but the washers under the pop-rivets will cover OK. The 0.002" SS foil is tougher than I thought it would be.
The FW with all the holes ready to be marked onto the foil.
The foil with all the holes drilled.
A piece of the 1/4" ceramic insulation that will fit into the recess.
