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All, I have just installed a set of oval hole panels that were made by Mike Coates. They are a very nicely done set of panels in aluminum. I purchased some perforated aluminum screen from McMaster-Carr some time ago with the idea to use it in openings like the rear panel area, side scoops, NACA ducts, etc. This screen is nice in that I think it looks good and it has a 79% open area which is the highest of any of the expanded/perforated metals I have looked at. After considering many methods of putting the screen behind the oval holes, I chose bonding at Mike's suggestion. I piped a bead of Lab-Metal ( Alvin Products ) around the underside of the lip formed by the return on the oval holes. I then pressed an oval of the screen with a lip of its own down into the lab metal and used my finger to form a fillet and make sure the metal putty had filled into the holes in the screen. Following up with a small sanding drum on a dremel left a nice shinny metallic fillet around the return.
I had made and oval die and plug out of wood that allowd me to press squares of the screen down through it to form a tight, square lip on the screen. A little trimming with end nipps and a small dikes had a nice lip to match the lip of the return.
Here are some photos of the results:
[ November 11, 2002: Message edited by: Lynn Larsen ]
I had made and oval die and plug out of wood that allowd me to press squares of the screen down through it to form a tight, square lip on the screen. A little trimming with end nipps and a small dikes had a nice lip to match the lip of the return.
Here are some photos of the results:



[ November 11, 2002: Message edited by: Lynn Larsen ]