RS Blog 4 - Fitting Cockpit Panels
Getting my feet wet
I’ve finally come to the time of cutting and drilling holes in things. Expensive things from the other side of the world. Things that aren’t easily replaced. If you haven’t figured out….I’m a bit nervous.
So I’m starting simple, cutting the aluminum paneling but not yet drilling holes in chassis to mount them.
Thankfully I’ve been working on cars and fabricobling things for many years now. My scroll saw is going to be very handy along with the band saw, newly aquired high speed air saw, Dremel with metal cutting bits and various files. I spent a bit of time before cutting the first panel to clean and situate the shop. Turns out I’m ready for this.
First up rear bulk head
Introducing new tools
I’m going to share some of my favorite and some new tools to my shop on this adventure. Some of them have simple functions such as drawing circles, while others are highly precise. Every tool has a purpose and they excel at that one task. When you find the tool suited perfectly to the job your life is on easy street.
This tool is beautiful. Gives the ability to draw perfect circles from 3mm to 70mm. I used it to mark the holes on my rear bulkhead for brake cables at 32mm.
Easy peezy and in style.
It isn’t perfect for centering holes, but these don’t need to be precisely centered for now, it is a mark for mockup before drilling.
Saving time by using clever tools, this evenly spacing guide allowed me to quickly mark out the spots for rivets. First marking a straight line, followed by measuring out 300 mm for a set of ten rivets. Adjust the tool for ten holes and voila easy marking for that full set of rivets.
I really enjoyed using the tool and will value it’s flexibility for any spacing.
Ultima uses a 30 mm spacing rivet pattern.
This tool wasn’t really necessary, however the Ultima has a mix of metric and standard measurements so my cheap dial caliper in inches wasn’t going to be too useful. I didn’t feel like converting that often and finally got real calipers.
Fitting various panels in the cockpit
Dremel + Air saw
This pair of tools is unstoppable when it comes to aluminum panels and fitment. The saw makes quick work of the bulk cutting, then follow up with Dremel and a metal cutting bit to finish out the shape.
Minor finish work with a file for the sharp edges and you’re done.
I’m trying to fit all the main panels of the cockpit via clamps before drilling any holes to make sure they all fit nicely. So yeah I’ve got all the clamps.
