Lonnie-S wrote:
Any help would be appreciated. I'm going to get some practice by making panels for the inside of the boot using the technique first, I think.
Hi Lonnie, not sure if I ever did a tutorial on making the nutplates tabs, but the process I used is below.
To answer your first question, the 2 lug nutplates I used allow the machine screw to wiggle around about 1/16” in all directions. This has been really helpful in fitting my panels and aligning the screw holes. Otherwise, I would probably have needed to use oversize washers here and there. Not an aesthetically pleasing solution.
My finished tabs are 1” tall x 1.5” wide with the hole for the #8 screw 5/8” from the weld edge of the tab.
My tab fab started with a strip of 1/16” thick cold rolled steel, 1.5” wide and a convenient length (2' - 3'). I marked a center line down the length of the strip and drilled a string of center holes at 1” intervals using a #19 bit.
Then using a nutplate jig from Aircraft spruce placed in the center holes, I drilled right and left side rivet holes with a #41 drill. Usually I drilled a string of right-side holes and then flipped the jig over and drilled the left-side holes.
The center holes were then opened to 13/64” to give the screws the wiggle room mentioned above.
The rivet holes were dressed with a 120* countersink for the flush-head rivets and the rivets test fit into said holes. Then the nutplates were riveted in place.
The steel strip was cut into 1” tabs along pre-marked lines using a horizontal band saw. The tab edges were cleaned up in the belt sander and the upper corners rounded to a ¼” radius.
Tabs were placed as needed on the chassis and tacked then welded in.
Panel holes were marked on the backside of the panels through the nutplate screw hole using a sharp awl. Panels were drilled to 11/64” for the #8 button head screws. A small-diameter round file (chain saw sharpener) was used to make any panel hole adjustments needed.
I used a LOT of these t@bs to make all my panels removable. Many happy hours on the drill press.
Hope this was helpful.