Cutting the panel

[redbowen]

Looking for solutions for having the panel layout cut. I have looked at some of the software options and also checked out the Panel design Up North Aviation - Home website. What have the rest of you done to get your panel design cut?

[efwd]

It seems a whole lot simpler if your using EFIS and the like. Big round holes for steam gauges might be more difficult, requiring special tools. All my panel holes were laid out using the Garmin templates they provide on line. Drilled the holes at the corners and cut out the edges with a jigsaw. All my switches were cut using a step drill bit. I just put the templates in place and taped them down before using a center punch at all the corners to mark my spots.

[tracstarr]

I'm currently working on mine now. I'm modeling it in aurocad and getting it locally. Talked to a few places and it will cost about 150 cdn including material. I can't use my existing panel material as it was cut by previous owner.

I'm just perfecting the template for my model 6. Started with template from another member but it was a bit off for me.

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[ken nougaret]

I guess I'm old school or really cheap. I drew my panel and then proceeded to drill many #30 holes close together. Then cleaned up with a file. It took time but came out nice.

[Dave S]

I guess I'm old school or really cheap. I drew my panel and then proceeded to drill many #30 holes close together. Then cleaned up with a file. It took time but came out nice.

I'm with Ken on this - cost was an issue for me and I am fine with old school. If a person is careful you can't tell it from a shop job. Very happy with the results. Quickest cut was trimming the outside edge with the bandsaw.

[redbowen]

I'm definitely looking for CAD options. I plan on flush mounting an iPad and an EFIS and really want a clean CnC or laser cut panel. I did the old school method on my model 5 and it turned out ok, but this one I want really clean and possibly laser etched labeling. Compared to other portions of the build, I don't find the professional cut panels to be unreasonable. I'm looking for advice on ways to produce the CAD file, on a Mac not a PC. There is Panelplanner, but the guy at Up North will do the entire design and cutting for the same price as the Panelplanner software.

[ejoern]

Bryan,

I had a great experince with Steve at Aircraft Specialty in Wisconsin. He worked with me and even sent a sample panel made of plastic to test fit everything before cutting the final panel from alumunim. I think we went though at least 15 revisions before I settled on the design. I also have a flush mount for the iPAD and an EFIS (MGL) along with the Garmin GTR200 radio, air vents, switches, etc. He would have my panel design already in CAD that you could use. I have a SS.

Eric Joern
cockpit view.jpg

[Delta Whisky]

I laid mine out using Draftsight (2D CAD, free until the end of the year), printed it out full size (Staples), glued it on the blank panel and then cut the round holes with either a fly cutter or a rotabroach and the square hole with a sabre saw/file. You can see in the pictures a change or two I had to make between the first CAD version and the final one.

[JimB]

Hi Everyone, long time lurker but this is my first post. I just placed my order for a 7SS kit (Est. delivery September 2020) but i'm looking to get a headstart on some of the design aspects before the kit arrives and the real fun begins.

Does anyone have panel dimensions or an accurate CAD model they'd be willing to share? I'm a design engineer by trade so I have access to all of the usual software platforms/file formats.

Many thanks!
-Jim

[Tom Waid]

I guess I'm old school or really cheap. I drew my panel and then proceeded to drill many #30 holes close together. Then cleaned up with a file. It took time but came out nice.

Like Ken, I'm old school. Dremel tools, files, and step drills. A lot of work but I'm very satisfied with the results. The process can be viewed here.