On 5/10/99, Paul Lowe wrote --
> To install the 6 main instruments, I was going to fit them to an aluminium
> plate, let into a rectangular cut hole in the panel.
> (i) Is 2mm strong enough or is 3mm required?
> (ii) What grade of aluminium should I purchase?
> (iii) As forgiving as composite material is, aluminium is not, especially
> when I cut it, does anyone produce a precut ali panel to hold these
> instruments, I don't want part of the instrument scan in the future, to
> include looking at a miss cut panel. I was going to use a re ground fly
> cutter, is there a better method?
> (iv) There are many fixing within the cockpit module, anchor bolts, nuts,
> bolts and hydraulic pipes, is there a light weight sound proofing material
> which can be used to cover the module, cut around these, to provide a flat
> surface for the upholstery?
Hello, Paul --
A fly cutter will make a mess on ali. But one way to cut the hole is use the
fly cutter to manually scribe the desired hole, then drill out a circular
series of holes within the scribed circle. Remove the hole and clean it up
initially with a rotary rasp or rotary file. Then finish with emery cloth
wrapped around a 2-inch or so wood dowel. I use a hood with magnifying glass
in front of the eyes (most useful Europa tool I have) for tasks like this, as
you can file away right up to the score with great accuracy with it.
The placement of the three or four mounting holes may not come out to your
liking without first making a drilling template. Recommended.
2 mm aluminum alloy (2024 would be OK, not commercial ali) is preferable, as
3 mm will recess the instruments too much for good appearance. The real
problem is, though, instrument spacing as, the closer together they are, the
floppier the assembly will be, whether aluminum or Europa's plywood sandwich.
Since panel space is limited, I'm planning on instruments which will reduce
the hole count (and weight too). Rocky Mountain Instruments
(http://rkymtn.com/rmi.htm) has a round 3-incher that will replace the
altimeter, airspeed, VSI, remote encoder, and even more if desired.
On the seat back hardware which will annoy the seat fabric, I would let it do
so and avoid the extra weight of protective foam. Vinyl can take it, and if
you use fabric (the sun will heat up vinyl nicely thru the door's "perspex"),
it will sooner need replacing anyway due to the abuse you'll give it getting
in and out. As to the brake hydraulic lines -- I will be running them
trough a channel fabricated from bid, down the left side straight back to
port side gear leg ribs. It will be located between the bottom of the
upholstered side panel and left side of the carpet. FAA in this country may
not like Europa's routing and potential chafing. Can you still do that?
Hope this helps! ---
Regards,
Fred Fillinger, A063
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