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Zenith CruZer & Sonex Logs
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Date: 8-3-2010
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Number of Hours: 1.20
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Manual Reference: SNX-D01
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Brief Description: Determining Panel Cutouts for MicroAir Radios
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This was somewhat frustrating. I spent quite a bit of time trying to measure-out angles and corner points on the panel stock last night, but I still could not obtain what I felt was a "square" alignment of the 4 mounting holes.
So, today I drew the layout in powerpoint. I used the adjustable gridlines to obtain 1/10", 1/8", and 1/16" spacing as required for the various holes. Fortunately, my printer output was 1-to-1 perfectly in scale with the as-drawn items.
I then taped the pattern to a piece of scrap stock (don't want to ruin the panel yet) and center-punched the cross-hairs for the center and the 4 screws. I did not use rubber cement to hold the paper to the stock, and I think that for real I may do so. As a matter of fact, I may make another scrap piece using rubber cement to see if the results are better. The problem was that as I was center-punching, I noticed the paper was bunching up ever so slightly. The result what that the initial drilling of the pattern resulted in two of the screw holes being about 1/64" off, which prevented the screws from going into their holes in the radio. I was able to fix this with a few swipes of the file, but the radio is ever-so-slightly off-center as a result. If you look for it, you can see the result in pic 3 below.
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What I drew on PowerPoint
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And transferred to scrap aluminum
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With the radio fitted in-place
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