I spent some time this afternoon playing with clear silicone caulk trying to seal the av-bay bulkheads wherever there was a hardware pass through in the plywood. Nasty stuff: Bad fumes, sticky, hard to manipulate, mineral spirits clean up. Next time I'm just going back to epoxy for the hardware and Tack-It for the wiring pass throughs.
Also bought some stainless steel #12 flat washers and 1/4-20 nuts at the local rocket store Lowe's. Today I learned that a #12 flat washer fits a 1/4-20 thread tighter than a nominal 1/4-20 washer.
I drilled out the static vent ports on the OSXP av-bay while I was messing with it. VernK has a nice table for determining the size of the ports at this link... Altimeter Port Sizing
Last thing I did was try to remove the molding marks on the 2.6" LOC nose cone that belongs to my OSXP project with coarse and fine Perma-Grit sanding blocks. Should have tried this before. The Perma-Grit raises the finest "hair" I've ever seen on a nose cone. The plastic primer is going to love it.
Thanks for the tip Kit, I had some of those, but forgot what they were. Much better fit.