July 4, 2007 - Panel |
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| With the Dynon's rectangular hole cut-out in the Panel, I turned my attention to the mounting bracket. First step was to drill the flanges. I figured five holes on the horizontal flanges and four on the veritical flanges would suffice. | ||||||
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| Next I back-drilled the bracket to the panel. I had to use my 12" #40 bit for this. Because of the aft flanges, it was challenging to drill the holes near the top of the bracket. I couldn't figure a way to drill the top horizontal row so I just left it undrilled. The instructions say you only have to drill the vertical or the horizontal flanges; you don't have to do both. | ||||||
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| I clecoed the mounting bracket to the panel. And then of course I just had to see how the Dynon looked in the panel. Looks great as far as I can tell. Alignment looks good. | ||||||
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From the rear.
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| I countersunk the #40 holes on the panel front. I took my time and worked very carefully, as the shop heads will be visible on the panel -- don't want oversize or undersize countersinks. Must be just right. All countersinks came out well. The Dynon was essentially done. | ||||||
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| I turned my attention to the "Stack" cutout. This time I didn't drill the #40 holes in the corner; that caused more trouble than it was worth with the Dynon cut-out. I just drilled the 3/4" holes near the corners. | ||||||
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| Once again, I used the jibsaw to drilled out the rectang.e | ||||||
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There are still the corners to deal with.
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| Instead of the dremel, I used my Exacto- saw to square the corners. This worked much better. | ||||||
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Then the inevitable filing. This History Channel had an excellent
series on the American Revolution so I enjoyed watching that while
filing.
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| The battery box temporary fitted to the firewall. Because the B&C Battery Contactor is taller than Van's, I have to move the battery box up about 3/8". I just drilled a nutplate holes to #12. I'm going to have to get some end nut-plates. | ||||||
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| Here you can see the manufactured flush heads of the rivets. | ||||||
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