Dear Nate, I think I know exactly why the two sides don't fit right.. I think I did the same thing and had to fight it for the rest of the build, so before you go too far it might pay off big time to stop by and have a chat and you can see what I am talking about. I wish I had noted it earlier as it would have save me a ton of headaches.
Nate, Welsome to the 801 Family, I can appreciate what you are about to do and what is involved as i just finished my 801 on Friday the 28th. I am giving you an open invitation to come down as see my project whenever you can make arrangements. If you need to call me I can be reached on my cell ph 608-728-0365. I know you will enkoy the 801 building process, there are a few tips and tricks you may be intersted in to save some hassle as you go along, so my door is open.
Custom instrument panels are now available directly from Zenith Aircraft Company exclusively for Zenith builders and owners. Pre-cut panel, power distribution panel, Approach Fast Stack harnesses, Dynon and Garmin avionics, and more.
Developed specifically for Zenith builders (by a builder) these videos on DVD are a great help in building your own kit plane by providing practical hands-on construction information. Visit HomebuiltHelp.com for the latest DVD titles.