10/18/2006
I wasn't thrilled about how the instrument panel sides turned out a few weeks ago. I had to put the ignition switch far on the right since I placed the vent hole too low. I had no idea the ignition switch would be as huge as it is. I ordered new parts a while back so I decided tonight would be a good time to redo it all.
This time I had all parts and measured everything carefully before cutting any holes. I used the flywheel cutter to do the vent holes, a Unibit for the starter hole for the ignition switch and the flap switch. I used a sabre saw to cut the holes for the trim indicators and ELT remote control box. I had to do a lot of filing to get everything to fit. I match drilled all of the #40 holes drilled out the two side rail holes to #12 and the nut plate center holes to #12. I then countersunk all of the #40 holes. Then I prep'ed with Precoat and Primed with PPG K-36. Whew. Busy night.
My plan is to continue working on anything that is easier to work on with the forward cabin skin off. Tomorrow I will rivet, touch up prime and paint the instrument panel sides. I will then install the components and wire them.