Brief Description: Cut instrument holes into panel plates.
Well, I answered my own question about my saw blade cutting straight, it didn't, even with a straight edge clamped to the plate. I finally got rid of the straight edge and just cut very slowly with two sets of reading glasses to see the line up close. I sawed just to the inside of the thin black line being very deliberate not to rush the job. After cutting the holes, I mounted the plates into the 5" vice and carefully filed away the aluminum until the line just disappeared. I now see why some guys go the computer software route and let someone else use a laser or water jet to cut the holes. But that is just more money that I didn't want to spend. The job is not difficult just tedious!
After getting the holes filed down and deburred, I slipped the Dynons into the holes just to see how they looked. They looked good! Tomorrow I'll get the trays clamped up to the plates to mark holes to drill for the riveting. I thought about using nutplates but decided that riveting the trays to the panels would be easier and faster. If later I want to change things, I can always order new panel plates and start over. That's the beauty of a modular panel.
Cutting the 0.090 panel plate with a saber saw.
Copius and tedious filing to get the proper dimensions.
