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Zenith CruZer & Sonex Logs
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Date:  5-15-2020
Number of Hours:  3.80
Manual Reference:  n/a
Brief Description:  Cut first panel holes; design & fab avionics rack

Took a deep breath and used a cutoff wheel to cut-out the panel openings for the comm and transponder. I then cut and fab'd side panels to provide rigidity to the racks; I put the xpnder on the bottom because it had the "far" mounting hole closer than the comm and I figured I didn't need too much length given only two boxes in the rack.

Installed the rack from the back, then slipped the LRU from the front because they're bezels are just a bit too big to go thru the holes - exactly as I want them!

I then determined how much slop I had with the comm/xpnder hole in order to tighten things up with the EIS hole, on top of the comm. The extra cost optional cast bezel adds a bit more room as well so had to dig that out and position to get a tight fit.

I then proceeded to work the L angles that go on either side of the rack to fasten the assembly to the panel front and additionally add some panel stiffness. Measured the bolt holes for the two racks and then determined the center spacing in the large opening to space it nicely. I will add additional L-angle to rack-side brace bolt at the top just to provide additional stiffness.

Still need to determine screw placement on the front of the panel so I don't interfere with the L-angle hardware.
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