26 MAR 2023 - Panel prep

Sumit Hours: 15

Overlay Panel received from http://www.upnorthaviation.com/vans-rv---10.html in November 2022 after providing CAD drawing review.

Overlay panel planned to sit approx. 17.1mm proud of F-1003A Instrument Panel. This matches the deepest bezel which is the G5. Other bezels: GDU 460 = 10.3mm, GMC 507 = 17mm. GTN 650xi (18.5mm), SL30 bezel (16.5mm), and Nextion touchscreen bezel (4.6 mm) depths don't matter as garmin trays and nextion screws will be set in Z-dimension location so that forward face of bezels are flush with the forward face of G5 & GMC507 bezels. GDU 460 will be set by adding 6.5mm shims to front face of F-1003A instrument panel in gdu perimeter locations.

Best technique to cut the rectangular instrument panel holes:

• https://youtu.be/Q97Uth88YCY
• Make outline lines using template or tracing instrument or by measurement
• Choose desired corner radius (typically 1/4" full diameter circle or per specific instrument dimensions)
• Mark corner hole centers using 1/2 of corner bit diameter (radius of bit)
• Drill a pilot hole and then use stepper/unibit to come up to full radius
• Use a straight edge and utility knife to scribe the straight cuts
• Use dremel EZ456 metal cutoff wheel at 15-20K rpm to join corners, staying inside of lines slightly
• Clamp straight edge steel to final line and use die grinder or dremel sanding discs to achieve final line
• polish and finish with files and/or scotchbrite

See mock up pic below for planned modifications to F-1003 INST PANEL LOWER FLANGE

Addendum April 2:

• absolute best technique to final line after clamping steel straight edge is 80 grit sanding disc twist lock on die grinder or corded electric high rpm drill
• same as YouTube link video metal magic
• much cleaner and faster than dremel sanding drum
• see pic below