Brief Description: Drill/Dremel Holes in Subpanel for Harnesses/Cable
Once I had the subpanel marked for all of the cutouts I removed the panel and went to work with a cutoff wheel in the Dremel tool. I had to take several breaks since the Dremel started to overheat. I used the flexible extension arm which seemed to contribute to the overheating.
The holes aren't the prettiest but they are functional and unseen behind panel. The reason they are rectangular is to accommodate the pre-wired Approach Systems harnesses.
I was able to make the cutouts and debur everything for the audio panel, the transponder, and the Dynon EFIS before my Dremel tool burned up, literally. I noticed a green flame coming out of the ventilation holes on the sides along with a very noctious smoke. I quickly unplugged it and thew it out of the plane onto the basement floor and opened all of the windows. Nasty. That's the second Dremel tool I've burned up on this project. I'm done with Dremel's,,,time to get something with a little more power.
I ended up purchasing a Craftsman 5.5 amp professional cutting tool. It's great! Plenty of power and torque, doesn't bog down using a cutoff wheel in the flexible extension arm and can use all of the Dremel attachments plus a bunch of it's own attachments. Very nice tool.
Audio panel cutouts on top; transponder on bottom. (Cutout for Comm in center done earlier)
