Instrument Panel Rack

I finally figured out how to attach the rack to the fuselage. I fabbed up some L-brackets to mate with the tabs on the rack, simple but effective. I trimmed the tabs back, used a couple of Adel clamps and temporary hardware to tighten it all up. Very secure. I'll finish sanding and powder coat the pieces once I'm completely finished mocking it all up.

Cargo Door

Once I finished fabricating the door opening. I measured it and it was about 4.25" wide at the base. Just too wide for the 4" finish tape I had on hand.  I put out feelers for a piece of 6" tape but no luck. Then I started asking if anyone had some scraps of Silver Oratex 600 fabric (thinner stuff). No response. So, I contacted Lars at Better Aircraft Fabric and asked if he had any scraps or if not, could he cut me a 6" wide piece off a new roll? He came through and sent me a scrap piece which worked exactly as planned.

I glued the surfaces yesterday and let them sit over night. I trimmed up the piece of fabric to fit pretty close. Then I attached it beginning in the middle and working toward the front, then the back. I trimmed the upper corners and sides and tacked it all down. It came out really nice.

Next up was to install the light switches. I had to cut the fabric from the holes and fish the wires out. I numbered the plugs, 3 per switch, so I would get them installed in the correct order. Once connected, I popped them into their respective holes and snapped them in place. Ready to go. I also trimmed out the slot for the locking mechanism on the opposite side.

The last step was to rivet the door on. Pretty straight forward, I used some sealant under the hinge to water proof it and the rivets going into the framework.

It closes up nice and tight, and I haven't added any weather strip to the door yet.

Panel Test Fit

I installed all of the bits and pieces into the panel to verify clearances once I had the panel mounted in the airframe. All fit well and had plenty of clearance for connectors.

Now I'm working on fabricating a shelf for all the "boxes" that mount behind the panel and connect to all this stuff...

Panel and Extreme Windshield

Not getting much done on the plane these days. It has been warm here as of late and is supposed to get hot for the next week or so, reaching 117 this weekend. However, I have managed to steal a few moments here and there.

I did get all of my bits installed into the panel to check fit and had to trim one item, do a little filing and cut a anti-rotation key slot. Everything fits great.

Then I started to fit the fiberglass former to the firewall. The bottom has to be trimmed so the top of the former matches the top of the firewall. I trimmed to bottom, leaving the sides to be trimmed later. I'll explain why in another installment.

 I also cut and fit the side L-brackets, drilled them and cleco'd them in place.

Panel Progress

I received the hardware I was waiting for to complete the install of the panel sides. I had to drill and dimple the side door pieces to accept the countersunk lock plates. I then riveted them in place and drilled out the panel sides to accept the 3/16" AN3-5 bolts. I then mounted the panel using the bolts, it fit perfectly, very sturdy with all six bolts in place. I will still anchor the "stack" in the center to the air frame which will make it all very rigid. To go a step further, I plan to Hysol the inside door frame pieces to the vertical fame for added strength.

I'm beginning to mock up the "boxes" that will mount behind the panel on a tray or trays. These boxes are the behind the scenes magic that brings all the electronics together. I have to figure out a way to mount them that will be convenient to route all the necessary wires as well as providing access for maintenance in the future.

So, to begin I am trying to figure out just how big a tray will be necessary? Will multiple trays be necessary or even wanted? How should the components be arranged? Is there a "perfect" configuration providing the shortest runs required to complete the connections? As well as other considerations.

After talking with my wiring guy, I think this layout will work well. If not, we can make any changes as we go. The boxes are: VPX PRO (electronic circuits), GEA-24 (Engine Instruments), GAD -29 (Bus Interpreter), GDL-51R (Sirius/XM Receiver), GD-40 (Carbon Monoxide Alarm), and a TCW Backup Battery. This is what I have come up with so far. The cardboard is representative of the tray with the length being cut off at the marker line just past the battery. The orientation would have the black box (Sirius/XM receiver) in the first pic on the firewall side and the battery on the left side of the cockpit. The box on the right side is the GEA-24 (engine instruments) and the box on the top of the pic is the GAD-29 (interpreter).

From the right side - GEA-24

Looking forward from the cockpit - GAD-29 and Backup Battery.

The red box is the VPX Pro Electronic Circuits

The black box on top is the GD-40 Carbon Monoxide Alarm

 At this time, I think the VPX Pro and GD-40 will mount on the underside of the tray making for a very compact grouping of components which are all tied together. Now to fabricate the tray and start mounting the components. Then I'll have to figure out how to mount the tray in the aircraft...

Extreme Windshield Progress

I cut the top of the Lexan firewall to the template. I can now start trimming the fiberglass former for the windshield base to match the height of the firewall.