Best way to cut a panel in place?

[Kooshball]

We will be putting a GRT sport EX in our -4 soon and have planned to just cut out a rectangle, install some aluminum and mount the GRT unit. We are not planning on replacing the whole panel.

Is there a preferred tool or technique that will generate the least amount of dust / mess? I want to avoid fine metal scraps or dust getting elsewhere as much as possible.

Thx

[uk_figs]

Not sure there is an easy way, on my upgrade I used a dremel with the 90 deg end and metal cutting wheel making multiple passes. Masked the panel and had a vac running with the nozzle taped on the panel. Still makes a mess though.
Figs

[RVDan]

I have used an aircraft router bit, and a die grinder or Dremel. Aircraft router bits come in #1 or #2, are somewhat tapered and freehand sidecut well. I can pretty much follow a line. They make small chips, no dust like a cutoff wheel. They like to turn fast.
I think Cleveland tool has them.

Don?t use the ones made for drywall. They don?t freehand in metal nearly as well.

[Jpm757]

HF sells a mini pneumatic sawzall (around $30) that I used to cut a rectangular opening. Worked well for the big cut, then files for the rest. Make sure you use a fine metal cutting blade. Cover area below with micro fiber cloths, they do a good job of catching the metal chips.

[larrynew]

Good suggestions above for the cutting. I would also suggest planning on how to best mitigate the aluminum dust created. I thought I had done a good job cleaning up after an in-place panel cutting but about 3 years ago, my 430W started acting funky (technical term). An avionics buddy had seen the symptoms before and helped me disassemble it and showed me the aluminum dust. Cleaned and no problems since.

[Funguy]

I used a Dewalt Oscillating MultiTool with a circular blade. It worked quite well. The advantage over a rotating tool like a Dremel is it cannot run away on you.

[rocketbob]

I use an air nibbler often when doing avionics upgrades. You can get them at Harbor Freight. Clamp some steel rulers onto the panel to for guides and lay up plastic sheeting to catch the chips. No dust using this method.

[JonJay]

Originally Posted by rocketbob

I use an air nibbler often when doing avionics upgrades. You can get them at Harbor Freight. Clamp some steel rulers onto the panel to for guides and lay up plastic sheeting to catch the chips. No dust using this method.

Same here but a manual nibbler. Takes more time but it is what I had in my shop.

[Ralph Inkster]

Dust / chip containment I suggest removal of all carpet & upholstery. Remove all avionics from trays. Duct or masking tape all switch wiring & exposed electrical buss components. Prep anything else you don?t want chips in. After cutting the hole, dislodge any stubborn chips with compressed air & finish with a vacuum- than repeat the cleanup steps again.
Just about as much effort as actually removing the panel itself.

[N941WR]

I used a body saw and it works OK. You have to be careful to hold the tool at the correct angle and not pull it out of the panel until it has stopped!