After fabricating the new instrument panel, I needed to bend the bottom. Unfortunately, the first brake was too small. I have a friend who does HVAC and they have this behemoth brake. It took some experimenting but we were able to get the panel bent.
Here is the panel installed.
The original Show Planes cover / instructions pre-date the -1 kit, and the frame previously was not pre-drilled. This creates some edge distance issues. I couldn’t use the exact spacing recommended, so after a little thought, I came up with the spacing below for the nut plates. Its not perfect in terms of edge distance, but its for nut plates. Just to be on the safe side, I made a backing strip. No need to introduce any cracks from vibration.
I used the cover and a light to match drill.
Then I drilled for the nut plate rivets.
Here is the final product.
I countersunk the cover. BUT, I started countersinking the wrong side. Whoops! I easily fixed it with some flox.
I believe I’ve mentioned this before, but there are two types of countersink bits out there. The one below… sucks. It takes a huge bite out of whatever you are countersinking, and is a pain in the rear.
I much prefer the countersink bit shown here.
To countersink the fiberglass, I used a backing strip to keep the countersink bit from wandering.
(Here is a picture of my flox countersink repair)