#1 working on the dome

I've received my 300mm alu dome few months ago but i haven't take time to work a lot on it until now...

The dome set includes 2 domes : the outer dome with laser cut and the uncut inner dome, an aluminum bottom ring and a High Density Plastic inner bearing adapter ring

 
One of the first step is to remove every laser cut panels from the outer dome, and deburr every parts.

inner of the outer dome during panels and pie panels removing

The next step is to put the dome together perfectly, without gap between the 2 domes
it's not so easy, you have to put the outer dome on the inner dome and find the optimal position where the 2 domes are perfectly against each other. you will probably need to sand the inner part of the outer dome to remove laser cut burrs  

inner dome sanded

outer dome on the inner dome with panels removed

after sanding hours here is the 2 domes :

inner dome

outer dome

outer dome over inner dome

I've marked with a pencil every hole, panel's emplacement on the inner dome
I've started by installing the holoprojectors. I've used a small drill 2.8mm and made severals small drills around the inside perimeter of the holo's place to be able to cut off the hole, when the hole was opened, after sanding, i was able to install the holoprojector. I've made the same on the 2 others holoprojectors.

After the holo's installation, i've decided to keep everything together without removing anything during the work on the domes to prevent bad replacements.

The next step for me was to open the pie panels (PP) on the top of the dome.

Before cutting anything, we must draw where to cut, the pie panels have to be cut off with a smaller size than the size of the outer pie panel part. I've used hex T-handles : 4mm for the right,top and left lines and 3mm for the bottom line.

I've used dremel with speed cutting disc for the left and right lines to start the cut
and used a small metal saw to open the 2 lines. 

the top and bottom cut were done with severals small drills on the inside of the panel

 and after filing and sanding, here is the result with 2 pie panels opened

and the result with a view from the top

next steps will be opening the logic displays and some lateral panels...