A little Aluminum work this morning.
Cut 1/4" plate with my aluminum cutting blade.
I get a really nice edge with this blade.
The deburring tool is great to quickly take any sharp edges off.
Then I measure where the holes go and use an auto punch to create center points. You press the auto punch and it pops making a divot.
In this case I'm cutting 6mm and 8mm holes with my drill press using WD40 as a cutting oil which is perfect for aluminum. There is double sided carpet tape between the two pieces to keep them aligned.
Mark the edges to trim off.
You can see two additional holes on the drawing. They were just in case I felt this needed any additional strengthening. Fortunately I won't need them.
Take the corners off with my bandsaw.
Round and finish the edges using a 2" belt sander.
After a little hand sanding I have this.
Bolts holes line up perfectly.
Here it is installed.
I've been trying to redesign my flight pedal mount, but finally I just went with the existing design and just dialed it in. However I'm using metal stops in the back and just press it against them and tighten from the front.
The cable cleanup and reorganization was in part to make the transition to flight mode cleaner and faster. My flight pedals were just interfering with a power supply, so I raised them a bit for clearance and moved the flight pedal tracks deeper into the back. The resulting pedal position feels great!
Earlier, I had mentioned that one of the reasons I wanted to redesign my button box is that my last button box interfered with where I wanted my flight throttle positioned.
My flight ergonomics now feel the way they should for the first time since I installed a bucket seat well over a year ago. Which is one reason I haven't been using it in flight mode much. I've been sort of fighting things with flight for a little while.
This should be a lot better.