[rwarre]

Ok I will admit my stupidity but I still need advice. So after ordering a second aluminum sheet to replace the first baggage floor which didn’t fit the way I wanted, I measured 5 or 6 times and made the cut plus ¼ inch. When I tried the piece it I still was1/4 inch too small. I thought about adding a piece of angle to the floor stiffener to take up the gap. The first floor I did came out fine. This is 6a

 

[Stoo]

Ok I will admit my stupidity but I still need advice. So after ordering a second aluminum sheet to replace the first baggage floor which didn’t fit the way I wanted, I measured 5 or 6 times and made the cut plus ¼ inch. When I tried the piece it I still was1/4 inch too small. I thought about adding a piece of angle to the floor stiffener to take up the gap. The first floor I did came out fine. This is 6a

Start with a poster board pattern. It's cheaper, easier to cut out and additional pieces can be taped on.
Stewart Willoughby, 6

 

[rv6n6r]

+1 on the cardboard pattern idea.
Nice thing is, it's just a flat piece of AL.
It's definitely worthwhile to keep some reasonably large sheets of .032 and 0.25 around. It sure came in handy for me during my build and even since for repairs and mods and such.

 

[flywithayres]

Try a “spiling” technique (like in wooden boat building) with the posterboard. This article has some pictures that explain the process.

Spiling (boat building) - Wikipedia

en.wikipedia.org

 

[rwarre]

Try a “spiling” technique (like in wooden boat building) with the posterboard. This article has some pictures that explain the process.

Spiling (boat building) - Wikipedia

en.wikipedia.org

I figured a three panel baggage floor is as good as two. So I made three panels. Can't tell the difference.

 

[wirejock]

The 7 baggage floors have a 3/4" lip on the aft end.