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Zenith CruZer & Sonex Logs
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Date: 8-7-2010
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Number of Hours: 3.00
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Manual Reference: SNX-E01
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Brief Description: Finished Panel Prep
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Took quite a bit of time to cut out the ELT remote switch opening, mostly due to its relatively small size. I started off by drilling a series of small holes around the perimeter, then cut through all of them with a dremel cutoff wheel. Used a combination of dremel and file to smooth out the bumps. Lots of trial and error. The upper and lower edges only had about 1/32" overlap by the switch, so I couldn't get too ambitious with the trimming, otherwise there would be a gap. Trim a bit, test it, trim some more, etc.
Located and drilled the 4 mounting holes for 4-40 hardware.
Next drilled all of the switch and breaker openings. I wanted a good fit so instead of a 1/2" drill, I used a 15/32" for the switches. I went to Harbor Freight to try and find a uni-bit with that size, but they were out of the one bit I needed. I then decided to cut the holes using my uni-bit which had the closest size at 7/16", then used a single-size 15/32" bit to up-size the holes the last 32nd of an inch. This worked well in the absence of the correct unibit. The breakers only needed a 7/16" hole, so the unibit worked just fine there.
I then cleaned up the panel and painted it. I had obtained a can of trunk spatter paint, thinking the gray and white splotches The result was less than I expected, so I removed all of the paint - what a waste.
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