Made a start…
Normally, if I wanted to clean up metal edges I would get my angle grinder out.
However, as the alloy is so thin, I'm sure I would grind off too much too fast if I did.
So it was back to hand files and sand paper to soften up all the edges.
I also drilled the first round of hole to fix the panels to the cockpit walls.
I only had time to do the rear wall panels.
I also knocked up a quick test piece and decided to use just a screw, not a screw and washer.
So to fix the panels I will need these three bits for my drill.
One to drill the hole in the alloy, one to drill a pilot hole in the wall & one to fix the screw in place.
Whilst this panel looks good...
The top edge of the panel was sticking a little bit too far.
The layer of Tetroseal I added may have something to do with this, or more likely operator error.
Either way, I had to spend some time marking and trimming the top edge to get a better fit.
So now I have to go back and smooth out this top edge again.
All was not lost though, as I was able to mark up where the main panel over lapped the passenger side corner panel.
So after drilling a few more holes, I was able to fix this in place.
Unfortunately, I managed to break my pilot hole drill bit.
But I had run out of time by this point, so I packed up for today and will try again tomorrow.
Cheers, Paul.