Flat bottom update!
I did manage to find a few mins and machine the flat bottom inserts and we were ready to start cutting.
Let's not screw this one up, that'll be expensive!
The inserts are machined to be able to use a counter sunk bolt so that we get the flatest flat bottom possible.
I will have a few small button heads protruding down in a few places because they make more sense, but for the main load bearing bolts I machined the inserts.
The insert has the center bore counter sunk, then a groove cut into the side and then two small holes drilled into the groove on opposite ends.
We take the carbon panel and drill the bottom side with a hole saw, just deep enough to penetrate the top layer of the carbon.
Then use a carbide bit to hog out the nomex so that the machined insert sits flush in it (full depth).
Next we use a tip top epoxy and inject it into the insert in the small hole, the groove in the side of the insert allows the epoxy to flow into the honeycomb full 360 degrees and by the time that the epoxy starts coming out of the opposite hole, it's done.
Definitely more involved than your average bolt and washer deal but oh so flat!!
Still need to put some finishing touches on it, but the first panel is getting close.