I need to make a new bulkhead panel for my RF. The original one didn't have the "ears" that bend and attach to the inner side panels, and it also had a bow in the aluminum sheet beneath the window opening to the engine compartment. The panel had been drilled and clecoed in place, but it is apparent that the part of the panel that is bowed wasn't clamped firmly to the frame member when the whole panel was drilled.
So the problem I'm faced with is how to precisely locate the holes that are in the steel frame onto the new panel. I obviously don't want to re-drill everything because it would weaken the frame...I want to re-use the existing holes in the steel frame. I figure I can use the old piece as a template and transfer the holes on one side onto the new panel. Then I thought I would cleco the new panel in place, along one side, clamp it into position so the metal doesn't bow this time, then somehow locate the holes on the other side. The only way I've been able to think of to do this is to tape some carbon paper to the steel frame where I need to locate the holes, then use a mallet to tap the panel all along the length of the carbon-paper-wrapped steel frame and hope that the existing hole show up as blank circles on the back of the new panel. I'm unsure whether this method would work and I'm looking for a better solution.
So the problem I'm faced with is how to precisely locate the holes that are in the steel frame onto the new panel. I obviously don't want to re-drill everything because it would weaken the frame...I want to re-use the existing holes in the steel frame. I figure I can use the old piece as a template and transfer the holes on one side onto the new panel. Then I thought I would cleco the new panel in place, along one side, clamp it into position so the metal doesn't bow this time, then somehow locate the holes on the other side. The only way I've been able to think of to do this is to tape some carbon paper to the steel frame where I need to locate the holes, then use a mallet to tap the panel all along the length of the carbon-paper-wrapped steel frame and hope that the existing hole show up as blank circles on the back of the new panel. I'm unsure whether this method would work and I'm looking for a better solution.