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  #1  
Old 11-28-2015, 06:51 AM
Far North Texan Far North Texan is offline
 
Join Date: Jun 2015
Location: Alberta
Posts: 84
Default Best way to make larger instrument holes in existing panel?

I am in the process of saying goodbye to my old Isspro fuel quantity, and oil temp/pressure gages. I am going to replace them with electronics intnl. guages.
The existing holes are 2", and the new guages require 2 1/4" holes.

What is the best way to open these holes up?

An instrument hole punch would be best I think but how do you keep it centered with a 2" "pilot hole"?

No doubt there is a tool for this but I don't happen to know what it is.
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  #2  
Old 11-28-2015, 06:58 AM
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mosquito mosquito is offline
 
Join Date: Feb 2010
Location: Hendersonville, NC
Posts: 186
Default +1 for the punch

I used a punch for this exact operation. Mark the new circle on the panel and get the punch started manually until makes contact with the panel and holds itself in place. I was very worried about keeping it centered but it turned out to be quite simple.

I've also done this operation with nibblers and a file... and that made an unholy mess of aluminum dust. I recommend the punch.

-jon
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  #3  
Old 11-28-2015, 09:20 AM
Far North Texan Far North Texan is offline
 
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Default

thanks much, I didn't know if it would grip and stay in position.
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  #4  
Old 11-28-2015, 11:53 AM
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flyboy1963 flyboy1963 is offline
 
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Location: Lake Country, B.C. Canada
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Default one method.....

I'm no machinist, but if you drill the 4 new instrument screw holes, then use these to attach a sacrificial square of aluminum behind the panel, this will be your pilot hole guide piece.
you can then use the punch, or a more primitive hole saw to cut thru the panel, and slightly into your scrap piece.
File, dremel, finish as needed.
Your local avionics shop may loan you a punch for the standard rental fee ( a case of Big Rock suds, or bottle of rye.
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Old 12-06-2015, 07:53 PM
Aero_Octaveus Aero_Octaveus is offline
 
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Location: Edmonton, AB
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Default Rye

Rye - Also known as Crown Royal down south
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  #6  
Old 12-06-2015, 08:28 PM
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bhester bhester is offline
 
Join Date: Jan 2005
Location: Hopkinsville, KY
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Default Punch

Once that punch starts to bite it is not going anywhere. Go slow.
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  #7  
Old 12-06-2015, 09:04 PM
Far North Texan Far North Texan is offline
 
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Default

thanks for all the input. I did find a hole punch for a good price and have it on order.
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