Spent 6 hours in the shop today working on the rear cockpit control cover. It was an iterative process. I printed the template I made up is Turbo CAD and then tested the use of it by cutting out the pattern onto a piece of poster board. Doing this also allowed me to determine a sequence of doing the bends so I don’t get myself into a corner. Once the template was done I test fit it and of course I had to make some changes.
After making the changes I cut out another version on poster board. I was happy with this one but will need to open up the hole for the control stick. Before I cut out the cover in metal I had to determine where I will attach the air vent. I took the 2” hose and laid it in and marked the cover with the vent location.
I updated the CAD file with the adjustment and air vent location and printed out the template. I am getting tired so I will wait until tomorrow to try by hand at cutting and bending the aluminum into the rear control cover.
Paper template test fit
Pattern cu onto poster board
Will need to make this a 2 piece cover. The front part will attach to the top at the bend with screws
