Well in an effort to make the airplane as easy to maintain as it is to build, I wanted go instrument panel access. No one like laying on their backs on top of the rudder pedals trying to trouble shoot avoinics, etc. There are several guys who have modified the F-866B-1 Upper Forward Baggage Bulkhead to allow for a hinged access panel.
I spent most of the time this morning thinking through what I wanted to do and how. I then layed out the hole on the bulkhead. I marked off where the lower bulkhead overlaps the upper. The bottom of the hole is 1.5" from the bottom of the bulkhead and the top runs an arc that is 1" below the edge. I measured 1" outboard of the 2nd to last stiffner indentation and then started cutting with my dremel cuttoff wheel - not fast, but I wanted to be careful. I left about 1/8 from the line and then will use my dremel bur attachement (looks end mill of sorts) and worked out to 1/32 and then I'll sand from there. I'll use a piece of .025 to make a doubler that will go on the aft side of the bulkhead and then use the other piece of .025 for the door itself. I might go with something thicker for the door later, but this is all I have on hand in my shop. I'll put piano hinge at the bottom (also an extra piece laying around and use nutplates and screws to keep it closed.
Should take about 6 or 8 hrs to complete.
Here is the hole layout. I used a 3/4" socket to draw the corner radius.
Cutting the hole - CAREFULLY!!!
Here it is! Look at all that aluminum dust - yuck!
