 |
Matronics Email Lists Web Forum Interface to the Matronics Email Lists
|
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
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
perfeng(at)3rivers.net Guest
|
|
Back to top |
|
 |
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
|
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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
--
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
|
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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
--
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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
--
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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
----------------------------------------------------------
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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
--
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
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"
| - The Matronics RV-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
|
|
|
Back to top |
|
 |
|
|
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
|
Powered by phpBB © 2001, 2005 phpBB Group
|