Panel replacement

Is the panel on a -4 a structural piece of the fuselage?

I had planned on cutting the old existing one out leaving about a 3/4" lip. New replacement would be cut to fit and bolted to that lip.

Is the panel on a -4 a structural piece of the fuselage?

Click to expand...

Yes it is.

So, what's the proper way to go about this?

New Panel

Recently re-did mine.
Order a new blank from Vans.
Take the old one out, only two bolts holding it in (minus the screws from the access panel).
Drilled out all of the rivets holding the top angle on that has all of the plate nuts.
Cut the bottom bend off of the old panel so we can use it as a template.
Used the old panel as a template to get the curve and and back drill the rivet holes for the top angle and the other mounting holes.
Used my mini cnc router to cut the panel.
Rivet the old top angle back on and mount it up.
Here are some pics of it.
https://photos.app.goo.gl/reuBqRW1BKspfd9b6

Also have a Fusion 360 CAD model of the panel if interested

I'm doing a similar route, but leaving the existing old lip in place and bolting the new one to it.

I'd love if you could send your template. I'll throw it in MasterCam and cut away. flyfastjp at protonmail dot com

Also, give me a call when you have a minute. I'd like to discuss this. 832 nine five five 2 seven five 4