Bill - Ditch the aluminum panel. You want glass with a large rounded
flange. An aluminum panel can act like a knife in an accident.
Had he a glass panel, one of my friends might still be alive.

Make a male mold for your panel by tracing the aluminum panel onto
a 1/2" plywood. Bandsaw it undersize by the new panel thickness.
Round the edges, smooth, varnish, mold release, then lay up your
new panel on top. Use a fine top glass layer and then lay smooth
mold-released surface over the glass to create a smooth pilot-facing
finish. Easy, quick, and a lot safer.

Hole-saws are easily available for the common sizes. Use some
old instrument cases for mounting-hole placement guides.

Hope this helps,
Best Regards, Dave

"Bill Daniels" wrote in message news:eezad.347181$mD.247702@attbi_s02...
I'm planning the installation of a new Borgelt B50 to replace an old Pirol
vario. The Pirol used three 61mm holes so the 57mm B50 units won't fit nor
will the G meter I'd planned to add. Arghhhh!

So, new panel time. Anybody got a new or used panel laying around?

If not, my choices seem to be:

A. A new panel from Shempp-Hirth or
B. Have one custom made by an outfit like Panel Pilot or
C. Make one myself.

I've made several panels and they are a LOT of work with a risk that the
part will be ruined at the last moment by the slip of a drill point. (been
there - done that)

Bill Daniels