Notched and filed two new face plate supports for the back pit's instrument panel.
Deburring instrument panel parts. Saw 2024 T3 is very soft. Will need to re-make several of the parts.
Fine tuning the fit of the instruments on the rear face panel.
Worked on the flange for the arched section of the back cockpit's instrument panel.
Filed and sanded smooth the flange for the top, curve on the back instrument panel. Match-drilled flange to the instrument panel.
Drilled the vertical rivet holes on the back instrument panel face plate and match-drilled both "U" supports to plate.
Measured, marked, drilled holes for circuit breakers on back cockpit's face plate.
Figuring out and fine tuning how and where I was going to drill the rivet holes in the back cockpit's main instrument panel.
Said the hell with that one face plate and decided to make all four new ones.
Measured location and cut holes in new instrument main panel for the back pit.
Cut the large opening in the center of the main instrument panel for the back cockpit. Checked the toggle switch locations, marked and drilled those out as well.
Drilling the back-side of the "U" channels then match-drilling them to the face plate of the back instrument panel.
Re-routed the face plate for the front pit. Used 6061 T-6. Seeing how easily scratched 2024 T-3 can be is what started me down the road of re-doing all in 6061 T6. Cut both 3 1/8inch holes too.
Routed 2 1/4inch hole in front face plate. Drilled and notched "L" flange for curve of front face plate too.
Drilled holes in front pit's face plate and then match-drilled "L" flange and "U" channels to it.
Drilled holes in front pit's main panel and match-drilled it to the "U" channels.
Drilled all the instrument mounting holes on the back cockpit's instrument panel; face plate and main panel.
Drilled instrument mounting holes in front pit's face panel.
Drilled holes in "L" flange for rivets. Cut, notched, bent and match-drilled "L" flange to the top edge of the back pit's main panel.
Match-drilled "L" flange to the front pit's straight, top, edge.
Drilled holes in 6ft of "L" flange. This will be for the "L" flange for the back of the "boxes" for each instrument panel.
More work on the "L" flanges for the back side of the instrument panels; drilled and notched 3ft of the stuff.
Cut, fitted and match-drilled "L" flanges for arched areas on both cockpit instrument back sides.
Cut, fitted and match-drilled both straight "L" flanges to the back side of the back pit's instrument panel. Cut and fitted up both "L" flanges to the back side of the front pit's instrument panel.
Drilled the holes in the "L" flanges, of the rear instrument panel, for the anchor nuts.
Measured and drilled holes for anchor nut plates.
Drilled the remaining holes for anchor nut installation on front instrument panel.
Making pattern for outer shell of back instrument panel.
Worked on cutting out the shell of the back pit's instrument panel and fitting it up to the front and back sides.
Aligning and marking holes in one instrument panel shell.
Two new instrument panel shell blanks cut out of .o32 aluminum.
Filed down both blanks to the marked lines. Ready for fitting up.
Rough cut, close cut, file and sanded to line one new sway wire fitting.
Rough cut three remaining sway wire fittings
Filed and sanded smooth... edges of three sway wire fittings
Bent all four fittings to either 150 degrees or 117.5 degrees.
Drill holes in all four fitting pieces.
Weld both halves of both fittings together.
Drilling rivet holes to attach anchor nut plates to the flanges of the instrument panels.
Drilling anchor nut plate holes again.
Half-way through countersinking the anchor nut plate rivet holes on the instrument panel flanges.
Finished counter-sinking the rivet holes.
Started riveting on anchor nut plates to flanges on the instrument panels.
Continued riveting... sames as above.
More of the same... riveting.
And... the same (riveting)
Finished riveting the anchor nut plates to the flanges. Just need to go back and drill out a few bad rivets and re-rivet and be done.
Drilled out several rivets from instrument panel for re-dos. Re-riveted those areas. Drilled corner holes in the back panels of both instrument panels for making lightening holes.
Cleaning up and filing the inside-edge of one of the instrument panel, back panels.
Same as yesterday except on the second panel.
Apr 5, 6
Spent both nights figuring out how to attach the instrument panels to the fuselage. Finally decided to wait until I had it all together to work on the idea more... I can take it apart easily to add a few brackets to it.
Spent the night testing the idea of a double flush and shaved rivet to fill in three holes. It works and I did the three holes. Nice !
More prep work on the instrument panels; re-riveted several anchor nut plates, cut down rivets and sanded/deburred the "L" flanges.
Worked on the sway-wire fittings. Cut and bent the doubler for each of the two fittings. Ready for welding...
Began riveting instrument panel pieces together.
Continued riveting the instrument panels.
Drilled out bad rivets from instrument panel.
More instrument panel riveting.
Cutting more rivets for instrument panel.
Drill out bad rivets from instrument panels.
More riveting on the instrument panels.
Cut and grind to size the doublers for the sway wire fittings.
More riveting of the instrument panels.
More riveting on the instrument panels.
Welded on doublers onto the sway-wire fittings.
Grinding off the old sway-wire fittings.
Ground off what was left of the starboard sway-wire fitting.
Ground off the second sway-wire fitting.
Filed excess weld puddles from sway-wire fitting areas.
Weld nicks in tubing.
Match-drill (8) 5/16inch holes in sway-wire brackets.
File and sand welds.
Riveted (using air tool) as many of the rivets I could on the instrument panels.
Welded on the first of the two, new sway-wire brackets.
Welded on second sway-wire bracket.
More riveting on the instrument panels. Just about done with them.