Scottie - Sounds like it was a nightmare, so at least it is done now.
So far I've only got the horizontal gearbox cover holes sorted out.
The only advantage I had was the fact I had to repair all the edges of the bulkhead, so I could drill the holes to match the cover.
Where did you get the foil matting from?
Initially I wasn't planning on insulating the cover, but it does look like a good idea.
Good luck, Paul.