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Rob,
I just finished cutting out my face sheets for my panel a couple of
months ago. I used a band saw to cut the outside edges and a disk
sander to clean them up. Then I cut out the instrument holes with
3-in. and a 2 1/8-in. hole saws. They wobble a little, so you have to
clean up the last 1/8 with sand paper. To do this, wrap a heavy duty
piece of 80 grit around the hole saw and duct tape the top edge. Cut
the sand paper so it forms a but joint and not an overlap. Sand to
the scribe lines you make when you layout the holes. Clamp the drill
in a vise and hold the face sheet as you sand. It worked well. I
didn't have to change sand paper more than about 4 times. It took me
about 8 hours to make both face sheets. After I have cleaned up the
edges a little more with finer sand paper, primed and painted, you
won't be able to tell that they weren't cut professionally.

Mike Reinath
360 MKII Std. Build
N3602M
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Please send your photos and drawings to marvkaye@olsusa.com.
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