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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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