Brief Description: Jig to duplicate the instrument panel
Took the existing panel, and a bearing guide tool in the router to cut a blank out of MDF.
Two problems: Bearing is small, panel is 0.080" thick. Panel needs to be about 1/8" inch above what is being cut to prevent the bearing from 'jumping' up and the carbide router bit to hog into the aluminum. Uh oh.
Hmm, cut two MDF boards out. Both with minor flaws, but used those to create a perfect nice MDF board that can be used as a guide to cut out new instrument panels.
Also picked up a 1/8" inch router bit. 0.125" -- Little bigger than the slots for the door hinges, but need to nicely cut the cowl. After looking at it some more, The Sorensen Clan had a nice solution in the way of a mini fairing around those slots/hinges. Hides any errors, and the fairing made easily (dowel, block of wood).
