First, mocking it up:
Second, drawing it out and printing on paper 1:1 to make sure it fits:
Third, sending it off to SendCutSend for cutting and waiting 5 days for delivery:
Forth, bending it. Badly.
Finally, cleaning, priming mating surfaces, putting some rivnuts in place, and then mounting it all together.
If you look closely, I have the rev 1 wing skins, so I'll need to cut my own access panel.
I've learned a few lessons about this, primarily that in the future, I'd stop the process at printing on paper 1:1, then transfer the design to aluminum stock myself instead of using a service. This is primarily because of the thickness of the materials. The thinnest aluminum they have is .040", which is super thick compared to what I'm used to working with on the plane. This could have safely been .016", but it's not available from any internet cutting service that I've found. This made it hard to bend without a brake (and I don't have access to one), and will be slightly heavier than it needs to be.
Overall, I'm generally happy with the way it came out. I'd love to hear what others have to say, or if you want the file or even a blank, I made a few extras I could send out.
