Matronics Email Lists :: View topic - Inst panel hole cutting

Matronics Email Lists
Web Forum Interface to the Matronics Email Lists

Get Email Distribution Too! FAQ Search Memberlist Usergroups Register

Profile Log in to check your private messages Log in

Inst panel hole cutting

Matronics Email Lists Forum Index -> RV-List

View previous topic :: View next topic

Author Message

dean.psiropoulos(at)veriz
Guest

Posted: Sun May 14, 2006 10:10 am Post subject: Inst panel hole cutting

Quick question folks:



I'm finally to the point where I HAVE to cut the instrument and engine

monitor display holes in my panel blanks.  I thought I had some folks close

by who could do that but in talking to them yesterday I discovered that they

really don't have the capabilities that I need.  I have a Dynon D-10 that I

want to flush mount and that requires a nicely made SQUARE hole. That could

probably be done with an old hand operated milling machine.  The biggest

problem though is the Vision Microsystems engine monitor display.  Its

outside edges are basically a square hole but at the corners, instead of

making them 90 degrees, they transition into something like a 45 deg angle

from the vertical lines to the horizontal lines.  Those of you who have

VM-1000 know what I'm talking about and needless to say, I'm convinced the

only way to get a nice looking hole to put this display in is to have it CNC

machined.  Since there is no bezel that fits over the top of this funny

looking hole, it has to be done right the first time or I'll be looking at

the botched workmanship every time I check my engine parameters.  Any

suggestions about how I'm might achieve this.  Is there anyone east of the

Mississippi river that has machining templates to do this or can I do it in

my shop with common tools somehow?  Thanks.



Dean Psiropoulos

RV-6A N197DM

Trying to get the wiring finished

perfeng(at)3rivers.net
Guest

Posted: Sun May 14, 2006 3:34 pm Post subject: Inst panel hole cutting

Dean,

An easy way to do it using "common tools" is to measure and make your own 

template.  Before you undertake several hours of measuring and layout you 

might try contacting the technical or production department and ask them if 

they have production drawings or 1:1 templates available.  If not there are 

several ways in which to transfer your demensions to your template.  You can 

either make the deminsions directly to a sheet of aluminum or draw it out on 

vellum and trace it using carbon paper backing.  Either way using a piece of 

Al or very thin polycarbonate the same face size as your panel area will 

allow you to position and size the unit along with allowing you to make all 

your cuts and trial fit prior to actually cutting your panel.  A good 

adjustable protactor saves lots of time laying out the off angles used. 

Just be sure you have the spacing in your sub. Oh BTW, a good machinist 

don't need no stinking CNC! 



Jim Duckett RV-7A  N708JD

---

bobbyhester(at)charter.ne
Guest

Posted: Sun May 14, 2006 5:41 pm Post subject: Inst panel hole cutting

You should be able to do it like I did. I used a jig saw at first I 

thought that idea was crazy, but it worked great! you cut it just a 

little shy and file to the finish line. You can read about it on this page:

http://www.geocities.com/hester-hoptown/RVSite/FinishKitAssyPg3.html



Please update your address book with my new email address:

bobbyhester(at)charter.net

Surfing the Web, Highspeed now, from Hopkinsville, KY

Visit my web site at: http://www.geocities.com/hester-hoptown/RVSite/

RV7A Slowbuild wings-QB Fuse-XPO360 engine 



DEAN PSIROPOULOS wrote:



 	  Quote: 	
		  



Quick question folks:



I'm finally to the point where I HAVE to cut the instrument and engine

monitor display holes in my panel blanks.  I thought I had some folks close

by who could do that but in talking to them yesterday I discovered that they

really don't have the capabilities that I need.  I have a Dynon D-10 that I

want to flush mount and that requires a nicely made SQUARE hole. That could

probably be done with an old hand operated milling machine.  The biggest

problem though is the Vision Microsystems engine monitor display.  Its

outside edges are basically a square hole but at the corners, instead of

making them 90 degrees, they transition into something like a 45 deg angle

from the vertical lines to the horizontal lines.  Those of you who have

VM-1000 know what I'm talking about and needless to say, I'm convinced the

only way to get a nice looking hole to put this display in is to have it CNC

machined.  Since there is no bezel that fits over the top of this funny

looking hole, it has to be done right the first time or I'll be looking at

the botched workmanship every time I check my engine parameters.  Any

suggestions about how I'm might achieve this.  Is there anyone east of the

Mississippi river that has machining templates to do this or can I do it in

my shop with common tools somehow?  Thanks.



Dean Psiropoulos

RV-6A N197DM

Trying to get the wiring finished

Bruce(at)glasair.org
Guest

Posted: Sun May 14, 2006 6:11 pm Post subject: Inst panel hole cutting

What you want to do is find a friend that has AutoCAD and have him layout

your panel on the computer. Then send the autocad file to a laser cutter and

volla, instant perfect cutout panel.



Wayne at www.engravers.net can cut your panel for you from your autocad

file.



Bruce

www.glasair.org

 



--

rv6n6r(at)comcast.net
Guest

Posted: Sun May 14, 2006 6:46 pm Post subject: Inst panel hole cutting

Jigsaw, files, hacksaw, drill -- worked fine for all of us "old-timers" who

built before laser cutters were in vogue. Its a bit of work but I doubt it'd

take less time than drawing on CAD.



Randall Henderson



 	  Quote: 	
		   DEAN PSIROPOULOS wrote:



 >

 <dean.psiropoulos(at)verizon.net>

 >

 >Quick question folks:

 >

 >I'm finally to the point where I HAVE to cut the instrument and engine

 >monitor display holes in my panel blanks.  I thought I had some folks

close
	


 	  Quote: 	
		   >by who could do that but in talking to them yesterday I discovered that

 they

 >really don't have the capabilities that I need.  I have a Dynon D-10 that

I
	


 	  Quote: 	
		   >want to flush mount and that requires a nicely made SQUARE hole. That

could
	


 	  Quote: 	
		   >probably be done with an old hand operated milling machine.  The biggest

 >problem though is the Vision Microsystems engine monitor display.  Its

 >outside edges are basically a square hole but at the corners, instead of

 >making them 90 degrees, they transition into something like a 45 deg

angle
	


 	  Quote: 	
		   >from the vertical lines to the horizontal lines.  Those of you who have

 >VM-1000 know what I'm talking about and needless to say, I'm convinced

the
	


 	  Quote: 	
		   >only way to get a nice looking hole to put this display in is to have it

 CNC

 >machined.  Since there is no bezel that fits over the top of this funny

 >looking hole, it has to be done right the first time or I'll be looking

at
	


 	  Quote: 	
		   >the botched workmanship every time I check my engine parameters.  Any

 >suggestions about how I'm might achieve this.  Is there anyone east of

the
	


 	  Quote: 	
		   >Mississippi river that has machining templates to do this or can I do it

in
	


 	  Quote: 	
		   >my shop with common tools somehow?  Thanks.

 >

 >Dean Psiropoulos

 >RV-6A N197DM

 >Trying to get the wiring finished

 >

 >

 >

 >

 >

 >

 >

 >

 >

 >

 >

 >

 >

 >

 >

 >

 >

 >

Bruce(at)glasair.org
Guest

Posted: Sun May 14, 2006 7:11 pm Post subject: Inst panel hole cutting

It took me a couple of weeks with autocad and my learning curve to layout my

very complex panel in my Glasair III. I can now do your average panel in

about an hour. When you throw in all the 3/4 ATI square, 45 degree corners,

VM 1000's and the other strange shaped stuff, it might take me 2 hours. When

I'm done, every thing fits, all the mounting holes line up. You might be

able to do it with a file, but you sure can tell when you look at the

finished product. If you're going to make layout mistakes, it's much easier

to fix the error on a computer screen than a sheet of aluminum.



Bruce

www.glasair.org

 



--

ronlee(at)pcisys.net
Guest

Posted: Sun May 14, 2006 8:22 pm Post subject: Inst panel hole cutting

There are places to scrimp and places to do it right.

The panel is something that you and everyone else will see

on every flight, on the ground, etc.



Ron Lee



Do not archive

aerobubba(at)earthlink.ne
Guest

Posted: Mon May 15, 2006 6:13 am Post subject: Inst panel hole cutting

HI Dean-



RE:  ...and needless to say, I'm convinced the

only way to get a nice looking hole to put this display in is to have it CNC

machined.... 



I have to agree here with the majority of the responses you've gotten so

far.  It's really not a big deal to do the panel well.  There should be

dimensional data for mounting your avionics available in your literature,

or at least on a web site.  Lay it out right on your panel blank, use

common drills, unibits, and a saber saw with a metal cutting blade as

necessary.  File carefully to a nice fit.  Test fit your avionics as you

go.  You will surprise yourself with how nice a job you can do.  



Virtually all the metal working skills I have I learned building this

plane.  All my avionics are face mounted, with only one bezel involved. 

The results are pretty gratifying.



FWIW- 



Glen Matejcek

aerobubba(at)earthlink.net

rv8striker(at)hotmail.com
Guest

Posted: Mon May 15, 2006 6:47 am Post subject: Inst panel hole cutting

I've read with interest this string and thought I'd add my two cents =

worth.



I found making the panel one of the more rewarding parts of the project =

and did it with a few basic tools. At first I called a few local shops =

with CNC machines and was shocked at the price just to do the hole for =

my VM-1000. I decided to get creative with the metal template provided =

with the VM-1000 and my trusty Craftsman router. First I mounted the =

template and blank panel on a piece of 3/4" MDF. Then using a straight =

cutting bit with a roller guide, made a very nice opening for the =

VM-1000 indicator.



After laying out the panel full scale on 1/4" graph paper I did the =

remaining holes with an instrument hole cutting punch. =

http://cleavelandtoolstore.com/prodinfo.asp?numberIHC318 Sure it cost =

150 bucks but it's the right tool for the job, does both 3 1/8 and 2 1/4 =

holes. The only other tool needed was a mounting hole jig, 14 bucks. =

http://cleavelandtoolstore.com/prodinfo.asp?numberIHT250I  (I'm a =

self admitted tool junkie so needing a couple of tools along the way is =

an excuse to buy one.) BTW I'm not partial to Cleaveland, Avery and =

others have them as well.



A little file work to open holes for things like the Kollsman knob and =

VS adjustment screw and that was it.



I've got pictures if anybody wants to see them off list.



Again, just my two cents worth but it worked for me.



Steve Struyk

St. Charles MO

RV-8, 45 Hours

ghinman(at)mts.net
Guest

Posted: Mon May 15, 2006 7:16 am Post subject: Inst panel hole cutting

I managed to make decent looking square holes using an

ordinary power jig saw with a mettle cutting blade.

Drill holes at the corners,then use the jig saw to cut

close to finished size.Then finish with a flat file.

You can do the corners with a small file.



 	  Quote: 	
		   I have a Dynon D-10 that I

want to flush mount and that requires a nicely made SQUARE hole. That could

probably be done with an old hand operated milling machine.  The biggest

problem though is the Vision Microsystems engine monitor display.  Its

outside edges are basically a square hole but at the corners, instead of

making them 90 degrees, they transition into something like a 45 deg angle

from the vertical lines to the horizontal lines.  Those of you who have

VM-1000 know what I'm talking about and needless to say, I'm convinced the

only way to get a nice looking hole to put this display in is to have it CNC

machined.  Since there is no bezel that fits over the top of this funny

looking hole, it has to be done right the first time or I'll be looking at

the botched workmanship every time I check my engine parameters.  Any

suggestions about how I'm might achieve this.  Is there anyone east of the

Mississippi river that has machining templates to do this or can I do it in

my shop with common tools somehow?  Thanks.



Dean Psiropoulos

RV-6A N197DM


	


-- 



George H. Inman

ghinman(at)mts.net

Bruce(at)glasair.org
Guest

Posted: Mon May 15, 2006 7:20 am Post subject: Inst panel hole cutting

Of the 11 holes in my panel, only 6 are round. The rest are 3 inch ATI,

(that's 3 inch square with 45 degree clipped corners), 1/3 ATI, rectulangar

(AOA), and my VM1000. Now you might be able to do a passing job by hand on

the big holes, but the real clincher is locating the instrument mounting

holes. If you're mounting with pan head screws you have some fudge factor to

oversize the hole if you're off a little bit. But all my instrument mounting

screws are countersunk. Which means I had to be dead nuts on. My Glasair III

has 5 metal sub panels that mount to a fiberglass frame. My cost to CNC all

the panels and holes was under $300 total. The cutter worked from my autocad

drawing, which I supplied.



Bruce

www.glasair.org

 



--

gerf(at)gerf.com
Guest

Posted: Mon May 15, 2006 7:31 am Post subject: Inst panel hole cutting

That's the way I went - one tip - put masking tape 2 layers 

thick anywhere the base plate of your jigsaw is going to 

contact the panel - mine got scratched up a bit as the saw 

travelled across the surface.



g



 	  Quote: 	
		   

 

 <ghinman(at)mts.net>

 

 

    I managed to make decent looking square holes using an

 ordinary power jig saw with a mettle cutting blade.

 Drill holes at the corners,then use the jig saw to cut

 close to finished size.Then finish with a flat file.

 You can do the corners with a small file.

 

 

 

 > I have a Dynon D-10 that I

 >want to flush mount and that requires a nicely made SQUARE hole. That could

 >probably be done with an old hand operated milling machine.  The biggest

 >problem though is the Vision Microsystems engine monitor display.  Its

 >outside edges are basically a square hole but at the corners, instead of

 >making them 90 degrees, they transition into something like a 45 deg angle

 >from the vertical lines to the horizontal lines.  Those of you who have

 >VM-1000 know what I'm talking about and needless to say, I'm convinced the

 >only way to get a nice looking hole to put this display in is to have it CNC

 >machined.  Since there is no bezel that fits over the top of this funny

 >looking hole, it has to be done right the first time or I'll be looking at

 >the botched workmanship every time I check my engine parameters.  Any

 >suggestions about how I'm might achieve this.  Is there anyone east of the

 >Mississippi river that has machining templates to do this or can I do it in

 >my shop with common tools somehow?  Thanks.

 >

 >Dean Psiropoulos

 >RV-6A N197DM

 


	


-- 

__g__



========================================================== 

Gerry Filby                                  gerf(at)gerf.com

                   Tel: 415 203 9177

----------------------------------------------------------

Terry Watson

Joined: 09 Jan 2006
Posts: 290
Location: Seattle, WA USA

Posted: Mon May 15, 2006 8:38 am Post subject: Inst panel hole cutting

Or maybe work from the back of the panel. But if you do, don't cut the notch

for the altimeter setting on the wrong corner. I hear someone did that. 



Terry

--

Jerry Cochran

Joined: 10 Jan 2006
Posts: 111
Location: Wilsonville, OR

Posted: Mon May 15, 2006 9:22 am Post subject: Inst panel hole cutting

Dean,

 

I have successfully used a router table to cut very clean and straight  lines 

on my panel. First, I cut with a hole saw, jig saw, or other means to  get 

close to the edge. Then with a small, .125" cutter in the  router, and a fence 

made from a piece of .063 alum angle one can  progressively take small cuts out 

to the edge you want. If you need smaller than  .125 radius at the corners, 

you can predrill those before routing. This method  results in a finish 

comparable to professional machining if you are careful, and  it is relatively fast 

compared to filing, etc... You will need to devise a  method to keep the fence 

solidly in place while routing but easy to move. With  mine, I simply use 

clamps.

 

You will need a variable speed control. Harbor Freight. Cheap.

 

It is important to practice on a similar piece and learn the technique  

first. 

 

Did I mention this is inexpensive? Provide you already have router access,  

of course.

 

Disclaimer and warning: Routers  can be dangerous cutting aluminum, so  take 

small cuts, say .003, push work against cutter rotation, not  with, or there 

could be an ugly surprise.  Wear eye  protection and leather gloves. FWIW, 

YMMV, etc.

 

Hope this helps

Jerry Cochran

Wilsonville, OR

 

 

In a message dated 5/15/2006 12:04:44 A.M. Pacific Daylight Time,  

rv-list(at)matronics.com writes:



Time:  11:10:30 AM PST US

From: "DEAN PSIROPOULOS"  <dean.psiropoulos(at)verizon.net>

Subject:


<dean.psiropoulos(at)verizon.net>



Quick question folks:



I'm  finally to the point where I HAVE to cut the instrument and engine

monitor  display holes in my panel blanks.  I thought I had some folks close

by  who could do that but in talking to them yesterday I discovered that  they

really don't have the capabilities that I need.  I have a Dynon  D-10 that I

want to flush mount and that requires a nicely made SQUARE hole.  That could

probably be done with an old hand operated milling machine.   The biggest

problem though is the Vision Microsystems engine monitor  display.  Its

outside edges are basically a square hole but at the  corners, instead of

making them 90 degrees, they transition into something  like a 45 deg angle

from the vertical lines to the horizontal lines.   Those of you who have

VM-1000 know what I'm talking about and needless to  say, I'm convinced the

only way to get a nice looking hole to put this  display in is to have it CNC

machined.  Since there is no bezel that  fits over the top of this funny

looking hole, it has to be done right the  first time or I'll be looking at

the botched workmanship every time I check  my engine parameters.  Any

suggestions about how I'm might achieve  this.  Is there anyone east of the

Mississippi river that has machining  templates to do this or can I do it in

my shop with common tools  somehow?  Thanks.



Dean Psiropoulos

RV-6A N197DM

Trying to get  the wiring finished

Rick Galati

Joined: 10 Jan 2006
Posts: 91
Location: Lake St. Louis MO.

Posted: Mon May 15, 2006 10:56 am Post subject: Re: Inst panel hole cutting

 	  dean.psiropoulos(at)veriz wrote: 	
		  ......... The biggest problem though is the Vision Microsystems engine monitor display......Those of you who have VM-1000 know what I'm talking about and needless to say, I'm convinced the only way to get a nice looking hole to put this display in is to have it CNC machined........... 	
Dean,

I did not find the VM-1000 hole to be particularly difficult to fashion at all.  As is my usual practice in approaching such things, I rough cut the hole opening as large as possible with a fiber cutoff wheel...the same one used to separate the canopy bubble...then using various high speed rotary files in a standard die grinder and a combination of smaller files and stones in a pencil grinder, I think the VM-1000 opening came out just fine.   

http://img478.imageshack.us/img478/7321/00001139tx.jpg



Rick Galati  RV-6A  "Darla"

Display posts from previous:

	Matronics Email Lists Forum Index -> RV-List	All times are GMT - 8 Hours
Page 1 of 1

Jump to:

You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum
You cannot attach files in this forum
You can download files in this forum