This is nearly exactly what I have done with my C182M. Musketeer, I used FreeCAD to draw the panel when I installed my Dynon Skyview HDX system. It turned out lovely. I've also done similar mods such as the door butlers which really are helpful keeping Cessna doors in check. For the panel, I created .STL files from FreeCAD and then took it to JAVRON in Brainerd, MN who happens to be 3 miles from my house. He specializes in J3 Cub kits (very enhanced with Roll engines and amphib floats) who took my STL files and a sheet of 0.090 6061-T6 Aluminum and within about 30 seconds it was cut on their laser cutter. There was a bit of polishing work to make the cuts perfect and smooth, then off to the powder coater for the final finish. I sent the panel to SteinAir outside of Minneapolis to laser engrave the required placards and the end result is in the airplane. The cut was extremely precise with all of the instrument holes perfectly aligned. I used the Dynon Installation manual to get the specs, and the Cessna Parts Manual which has to-scale drawings. They needed to be corrected for aspect ratios and actual panel height and width, but came out nearly perfectly the first time. I used the cardboard and lucite panel for rough fit and hand cut the cardboard and plastic, then made adjustments. Before I cut the final aluminum, I found a scrap piece of very thin (too thin) aluminum and laser cut the piece, glued some popsicle stick stiffeners to it and slid it into place, checked the fit of the PFD and controls and screw fits and it was perfect. Cut the final and the panel went together rapidly after that. To the author: I wish I'd started my project 3 months later, then I would have seen all your great ideas and confirmed that I did indeed to the job right. I'm going to pass this on to my IA so maybe he won't think I'm crazy anymore.
That's exactly what I want to do with my instrument panel. Do you mind telling who does the cutouts in the paper and aluminum, and does the laser etching?
This is nearly exactly what I have done with my C182M. Musketeer, I used FreeCAD to draw the panel when I installed my Dynon Skyview HDX system. It turned out lovely. I've also done similar mods such as the door butlers which really are helpful keeping Cessna doors in check.
For the panel, I created .STL files from FreeCAD and then took it to JAVRON in Brainerd, MN who happens to be 3 miles from my house. He specializes in J3 Cub kits (very enhanced with Roll engines and amphib floats) who took my STL files and a sheet of 0.090 6061-T6 Aluminum and within about 30 seconds it was cut on their laser cutter. There was a bit of polishing work to make the cuts perfect and smooth, then off to the powder coater for the final finish. I sent the panel to SteinAir outside of Minneapolis to laser engrave the required placards and the end result is in the airplane. The cut was extremely precise with all of the instrument holes perfectly aligned. I used the Dynon Installation manual to get the specs, and the Cessna Parts Manual which has to-scale drawings. They needed to be corrected for aspect ratios and actual panel height and width, but came out nearly perfectly the first time. I used the cardboard and lucite panel for rough fit and hand cut the cardboard and plastic, then made adjustments. Before I cut the final aluminum, I found a scrap piece of very thin (too thin) aluminum and laser cut the piece, glued some popsicle stick stiffeners to it and slid it into place, checked the fit of the PFD and controls and screw fits and it was perfect.
Cut the final and the panel went together rapidly after that. To the author: I wish I'd started my project 3 months later, then I would have seen all your great ideas and confirmed that I did indeed to the job right. I'm going to pass this on to my IA so maybe he won't think I'm crazy anymore.
That's exactly what I want to do with my instrument panel. Do you mind telling who does the cutouts in the paper and aluminum, and does the laser etching?