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Tip: Forming Instrument Panel Flanges

flion

Well Known Member
It's not much of a tip, but if you use the stock flanges (F-1003C, D, and E) to mount your panel (which I am doing, even though it's a custom panel), then the method in the plans may not produce good results. The F-1003C is fine but the F-1003D and E are cut from .032 angle and then need to be formed to match the curvature of the panel top edge. The instructions call for fluting but I fluted the c**p out of the angle and not only did not get enough curvature but the flange that lays against the panel was wavy beyond redemption. So I tried again, this time using a bench shrinker. This time I got a flange flat where it meets the panel and a good curvature match to the top skin.

I haven't had to use the bench shrinker/stretcher very much but when I have, the results have more than justified the cost of the tool.
 
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