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05-16-2011, 08:47 PM
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Join Date: Jan 2005
Posts: 68
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Cutting USB Holes
Back working on panel .. don't mind all the big GRT holes EXCEPT the USB holes .. never can get them to look great. Anyone got any good ideas how to cut these well? I always use a very small file .. but with 090 it's a real pain and never straight.
Thanks..
DWS
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05-17-2011, 01:32 AM
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Join Date: Nov 2007
Location: Gosford, NSW, Australia
Posts: 45
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I'm no where near up to this, and don't know the dimensions for the USB, except for looking at the back of my computer and guessing. But I saw very recently someone had done some narrow rectangular slots by using a Dremel with a router bit. You can get various sizes so I imagine you could do that and just square off the corners with a file?? Assuming of course you have, or have access to, a Dremel. When I saw what was done, and knowing I want to put USB in the panel, that was the technique that I thought I would explore for that purpose when I got there.
DAZ
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05-17-2011, 03:08 AM
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Join Date: Mar 2005
Location: Las Vegas
Posts: 149
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How about these?
A bit larger than needed for this but they are pretty and fairly easy to install, 7/8" hole if I remember correctly. I use them at work for racks from time to time.
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9a Empennage
#91208
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05-17-2011, 06:07 AM
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Join Date: Oct 2005
Location: 08A
Posts: 9,500
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You can cut a USB hole with nothing more than a drill and a file, in a painted, finished panel, in the airplane. Patience, patience.....
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Dan Horton
RV-8 SS
Barrett IO-390
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05-17-2011, 07:08 AM
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Join Date: Jul 2007
Location: Madison, Wisconsin
Posts: 778
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Could also cut down one of these to use as a mask if you've already made a too-large hole:
http://www.datapro.net/products/usb-...late-dual.html
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Alan Carroll
RV-8 N12AC
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05-17-2011, 08:53 AM
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Join Date: Nov 2008
Location: Missoula, MT
Posts: 714
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Nibbler
Don't know the exact dimensions, but a nibbler might work, then dress up with a file.
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Bryan Douglass
=VAF= 2020 dues paid
RV-10 N242BD
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05-17-2011, 09:10 AM
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Senior Curmudgeon
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Join Date: Sep 2005
Location: Dayton Airpark, NV A34
Posts: 15,420
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Nibbler is too big, if you are trying for a minimum sized hole.
I drilled a couple holes at the ends of where I wanted the slot, used a coping saw to open up the slot, and a file to finish it off.
Works well.

__________________
Mike Starkey
VAF 909
Rv-10, N210LM.
Flying as of 12/4/2010
Phase 1 done, 2/4/2011 
Sold after 240+ wonderful hours of flight.
"Flying the airplane is more important than radioing your plight to a person on the ground incapable of understanding or doing anything about it."
Last edited by Mike S : 05-17-2011 at 09:29 AM.
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05-17-2011, 08:03 PM
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Join Date: Feb 2010
Location: Toronto, ON
Posts: 82
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__________________
RV6, Flying C-GOFG
CLA4 - Holland Landing
Toronto ON
Donated to Dec 2020
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05-17-2011, 09:18 PM
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Join Date: Nov 2005
Location: Davis, CA
Posts: 1,156
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Quote:
Originally Posted by DanH
Patience, patience.....
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Sure......
__________________
Lars Pedersen
Davis, CA
RV-7 Flying as of June 24, 2012
960+ hours as of June 30, 2020. Where did the time go?
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05-18-2011, 06:44 AM
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Join Date: Nov 2005
Location: Asheville, NC
Posts: 2,692
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End Mill
I used a mill and a 1/4" bit to cut a 1/4 by .530" slot. Male USB slips right in.
Image below shows 2 slots just to the left of the EIS.

__________________
Bill Pendergrass
ME/AE '82
RV-7A: Flying since April 15, 2012. 850 hrs
YIO-360-M1B, mags, CS, GRT EX and WS H1s & A/P, Navworx
Unpainted, polished....kinda'... Eyeballin' vinyl really hard.
Yeah. The boss got a Silhouette Cameo 4 Xmas 2019.
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