Cut Panel

Today I cut the panel for the main EFIS screens and the sub modules. I measured and compared to the CAD probably a dozen times, and luckily it all came out straight and even.

The first thing I did was look up how much the blank RV-7 panel costs on vansaircraft.com -$40. With that knowledge, I began to cut the first sub module hole, the knob panel.

After the knob panel went smoothly I began on the second one, the AP panel. All the modules are the same dimensions, but with the variability in my hand cuts I checked and lined up each element after test fitting.

The process begins by drilling a 1/8” hole in the corners (1/16” radius). Then using a cutoff wheel I cut just inside the lines for the hole. Then I filed the edges to the final size so that each item fit perfectly, but with no catches or tight spots. Then using some scotchbright, I smoothed the edges out so they are soft to the touch.

Here are the four modules sitting in the panel. I need to buy some mk2000-6 nut plates so that I can screw these to the panel.

Next I cut the large hole for the main Dynon HDX displays. It was very satisfying when the display was installed. Many years to get to this point!

Finally I cut the second hole, making sure everything lined up and was square, and then test fit the second display.

One thing I was (and still am) a little concerned about, is the angled ledge on the displays. With the gap below being just less than 2”, I planned to install my toggle switches centered between the display and the bottom of the panel. But with the ledge of the display sticking out a bit, I might bias the switches lower to give myself a little extra room to be comfortable flipping the switches.

Once I finalize the position of the Garmin G5 I’m going to install just to the left of the pilots display, I’ll start drilling the holes for the toggle switches. I placed one just below the screen in order to see how far up and down the switch is when toggled. It should have plenty of clearance from the display.

Cut Panel

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