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We read about a different method on
another builder's web page (but can't remember their name). Cut a
wood panel with 1/2" space all around (top and cutouts). Put packing
tape on the aluminum skin and side rails to allow the bondo to release.
Temporarily fit the wood panel in place and squeegee
bondo in between the wood panel and the skins/side rails. After it
hardens, remove the top skin and the panel.
Total time was about 5 hours including cleanup. The router sprayed metal chips all over the garage - even with the shop vacuum attached. That was worst part of this entire process. 3 months later, we're still finding those little bits of aluminum. |
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Van's manual suggests lofting a line back on to the rear
of the panel and going through a repetitive process of cutting and
fitting.
When
finished, remove the wood panel and clean up any rough protrusions of
bondo. If you've squeezed enough bondo in between the panel and the
skin, you should have a perfect outline of your aluminum skin that is
transferred to your wood panel. It helps to have two people putting
in the bondo. One to mix and squeegee, the other to lay on their
back inside the plane to keep the bondo from gushing out the back (forward
side) of
the panel. This helps get a good, wide seal against the aluminum, and
it helps reduce the work of the next step.
Sand
the bondo down on one side of the panel (we did the foreward side) so your
aluminum panel blank can lie flat on the wood/bondo template.
Rough
cut the aluminum panel to the approximate shape, clamp to the template
(this is where it helps to have a flat surface on one side of the bondo) and use a
carbide flush trim bit on a router to transfer the shape to the aluminum.
When
finished, your panel will slide into place with a perfect fit.