June 30, 2007 - Install Mapbox into Panel

I've probably spent 15 hours planning the electrical system and panel.  But I'm pretty much done with the planning.  It's time to get on with it and start cutting.  I decided to start with the Mapbox figuring it's the least critical of all the rectangle cuts and it would be good practice.  Van's Mapbox kit comes with a drilling template so I positioned it where the drawings indicate and drilled all the #40 and #30 holes.  The #40 holes are for the rivets to hold the mapbox to the panel.  The four #30 holes indicate where the panel should be cut out. 
I couldn't resisit clecoing the mapbox to the panel.
The mapbox is so long that you have to cut a hole for it in the Subpanel.  But where?  The drawings give you a horizontal dimension to use but not a vertical.  I ended up using a square to mark where the mapbox passes through the subpanel.  You also have to cut a piece off the forward canopy deck (F-721A).  
Time to cut the panel.  I made four large holes with the Unitbit. 
Then I used my Jig Saw with a metal cutting blade to cut the rectangle out.  It worked pretty well.  The tape served two purposes:  to show me where the cutting line was and also to protect the panel from scratches by the jig saw. 
Once the rectangle was cut out with the Jigsaw, I had to use my dremel tool and file to true the edges.  I still have more filing to do but here the panel is with the mapbox clecoed on. 
Then I did the same thing to the subpanel.  It was easier to use the jigsaw on the Panel than the Subpanel because the subpanel is thiner and flimsier.
All done.
Next thing to do was trim the forward canopy deck -- along the purple line. 
I hate using the Dremel tool and cutting disk for rip cuts.  Thankfully, I was able to use my Exacto-saw which did a nice job without the stress of the dremel tool. 
I put everything back together.  My vertical measurement on the Subpanel was a little off.  The mapbox is resting on the bottom edge with a little more space along the top edge than there should be.  Not that big a deal, though.  I'll be putting angle along the top and bottom edges of the subpanel anyways.  The horizontal distances are perfect.
Looking from aft. 
As always, I didn't get as much done as I'd have liked.  But at least I'm finally started on the Panel.  Just getting that initial start is always the hardest part. 
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