Oct 10, 2023     New N-number placard - (0.4 hour)       Category: Instrument Panel

With the help of my friend Jim, I installed the new placard with the black screws I just received. It looks a lot better than the previous placard.

  Oct 06, 2023     New N-number placard - (0.5 hour)       Category: Instrument Panel

Accomplished the following wIth the help of my friend Jim:

1. Removed the "1st gen" N-number placard (silver with black letters). We had to go through the avionics access door in order to reach the locknuts.
2. Used the old placard to match-drill the "new and improved" one (black with white letters).
3. Ordered some new black-oxide 4-40 socket-head screws to attach the new one.

  Sep 24, 2023     New N-number plaque - (0.5 hour)       Category: Instrument Panel

A while ago I made an n-number plate for my panel, and being bright aluminum with black letters, it was certainly easy to read. However, it just didn't go with the "military look" of the rest of my panel. So, I recently had one made with white letters on a black plate, with a border around it. I think it will look a lot better. The signmaker even gave me some extra copies so I could practice drilling the two mounting holes, which have to match the existing holes in the panel.

Today I marked, centerpunched, and drilled the holes 1-19/32" apart on one of the practice plates. It came out nice, so I will use this plate as a drilling template on the real one.

  Feb 01, 2022     Cockpit RAM ball mount - (1 hour)       Category: Instrument Panel

1. Primed and painted the backing plate for the RAM ball mount. I used flat-black paint to match the powder-coated rollbar.

2. Installed the RAM mount and backplate, using three low-profile hex-head machine screws and Nyloc nuts.

  Jan 31, 2022     Cockpit RAM ball mount - (1.3 hours)       Category: Instrument Panel

Began working on the installation of a RAM mount on the right side of the canopy bow in the front cockpit:

1. Cut a piece of cardboard and used it as a template. Trimmed the template to fit the available space, then marked three locations for attach screws. (I picked the only three holes in the RAM mount that I could use without drilling into the aircraft structure.)

2. Transferred the template shape to 0.063" aluminum, cut out the piece, and used the template to locate and drill the holes.

3. Test-fit the plate and the ball mount to the airplane, and it was perfect! (The jam nuts will be replaced with Nyloc nuts later.)

4. Sanded and scuffed the mounting plate, in preparation for painting it flat-black.

  Dec 23, 2020     Panel assembly; wire lacing; external power cable - (3.2 hours)       Category: Instrument Panel

1. Continued wire-lacing various harnesses, mostly on the wings this time.
2. Wired up the Powerlet plug that will provide external power for maintenance purposes. Used 25 feet of 12 AWG, 2-conductor wire that will eventually connect to my 13.8V, 25A bench power supply.
3. Re-installed all the items on the right instrument panel, after it was re-painted and relabeled. (This time I took it really slow and taped off EVERYTHING to prevent damage...) I am back on track with the instrument panel now.

  Nov 24, 2020     Annunciator panel - (2.2 hours)       Category: Instrument Panel

After assessing the lamp assemblies (see yesterday's entry), I finished assembling the annunciator panel:

1. Finished repositioning the wires inside the annunciator panel, closed up the back plate, and trimmed all wires to the same length.
2. Stripped wires and crimped on all connector pins. Ran wires through braided overwrap. Inserted pins into CPC connector shell. Strain-relieved wires and wrapped with silicone tape.
3. Assembled CPC connector.
4. Installed annunciator panel into the panel. (You might notice that the annunciator panel is now behind the instrument panel, with just the lights showing through. This was a late design change in order to facilitate easier removal of the unit for maintenance. I think it actually looks better this way.)

The annunciator panel itself is now done! Hallelujah. What a project it's been.

  Nov 23, 2020     Annunciator panel harness - (3.5 hours)       Category: Instrument Panel

Continued assembling the wiring harness for the annunciator panel:

1. Soldered all 14 wires to the backs of the LED lamp assemblies, Had some major issues with the lamp leads becoming internally detached from the dropping resistors inside the housings, due to the brief heat of the soldering iron. After trashing two lamp assemblies, I figured out how to solder the connections without applying any vertical pressure to the leads. Got all nine LEDs soldered successfully, and put heat-shrink on all the power connections. Tested all nine lamps. Coated all exposed ground leads with liquid tape.
2. Labeled and prepped all wires for crimp pins. Began shaping them into a tight harness.
3. Modified panel housing to accept the thickness of the harness.
4. Began feeding the harness through the back of the housing, and discovered that the backplates of the LED shell assemblies don't have much structural strength -- or rather that they are simply press-fit into place. If you apply a bit of sideways pressure, the backplates can just pop off. Devised a two-part plan to secure the LED shells. First, I used CA glue on the seams. After it dried, I coated the entire shells with more liquid tape. I will let everything dry overnight and reassess the situation.

All in all, I do not recommend using these types of LED assemblies, and I probably won't use them again. (In the end , they are going to work just fine as annunciators once they are installed, but the struggles to get them to work in this application are just not worth it.)

  Nov 19, 2020     Annunciator panel - (1.9 hours)       Category: Instrument Panel

1. Printed, applied and installed the labels in the annunciator panel lenses.
2. Cut all wires for the panel-side of the annunciator display. I'm just waiting for a diode and a CPC connector to be delivered, and I will being final assembly of the display.

This final version of the annunciator panel only features five of the six blue lights being used, so I had one extra. Guess which one it is.

  Oct 12, 2020     G-meter, FCP Seat heat switch; RCP air vent - (2.1 hours)       Category: Instrument Panel

1. Finished fabricating the mounting system that will hold the RCP air vent, while still allowing the cover plate to be removed easily for maintenance. (The two right-side screws will fasten the vent, plenum, and backing plate to the airframe-mounted "tabs," while the two left screws will only fasten the cover plate to the vent, plenum and backing plate. This arrangement was necessary to allow the cover plate to sit flat.)
2. Installed a 4-pin Seal-All connector in the wiring for the FCP seat heat switch. Again, this is to facilitate easy maintenance of the fuel selector, or anything else below the left floor panel where the switch will be located..
3. Installed G-meter in panel, using new black screws.

  Oct 11, 2020     Instrument panel assembly; RCP air vent - (1.5 hours)       Category: Instrument Panel

.1 Continued assembling the instrument panels -- specifically, the main switch panel today.
2. Worked on the design of the RCP air vent attachment, which is particularly tricky because of the way I'm going to mount the vent plenum and the cover plate. I think I have it figured out.

  Oct 08, 2020     Panel assembly - (3.2 hours)       Category: Instrument Panel

1. Began installing instruments and switches in the main and side panels. Also installed some switch guards and covers.
2. Installed flap switch assembly into switch subpanel (no photo).

I am really pleased with how things are looking!

  Oct 01, 2020     Circuit breaker panel - (2.3 hours)       Category: Instrument Panel

1. Assembled circuit breaker panel, including 18 C/Bs, the USB port, the 12V/charging port, and the toggle switch.
2. Installed bus bars on C/Bs.
3. Continued fabricating backing ring for RCP air vent.

I am really pleased with the way the C/B panel looks. It's fun to see what was previously only in my head start coming to life at last!

  Sep 28, 2020     Panel clear-coat - (2.1 hours)       Category: Instrument Panel

This entry represents my part of the process of clear-coating the instrument panel. (The actual painting was done by my friend Jim K, but I did a lot of prep work!). The results came out really great, They have just the right amount of flattener so they're satin and not too shiny.

  Aug 14, 2020     Panel graphics - (3.5 hours)       Category: Instrument Panel

This entry covers the completion of the silk-screened graphics on the instrument panels, circuit breaker panel, and switch panel. They will have to be clear-coated before further assembly can begin.

  Jul 10, 2020     Pre-painting prep - (2.5 hours)       Category: Instrument Panel

1. Sanded down all of yesterday's "disappeared holes" along the edge of the right side panel.
2. Opened up and deburred all mounting holes on the panel attach angle that attaches to the glareshield skin.
3. Countersunk all holes on the right side instrument panel.
4. Prepped, primed and sanded the right panel and more fuselage panels for paint.
5. Cleaned FCP seat components in preparation for stripping,

  Jul 09, 2020     Countersink side pieces; paint prep - (3.8 hours)       Category: Instrument Panel

1. Filled several holes that resulted from having to turn a nutplate sideways to accommodate my G3X screen. Filled other holes in the side instrument panels that resulted from a test fit of them revealing that the mounting holes had to be moved slightly.
2. Used a DA sander to sand the face of the main instrument panel, then sanded it with red Scotchbrite. Cleaned, prepped and primed the panel with self-etching primer.
3. Counter sunk all attachment holes on the left instrument panel.
4. Lightly sanded more fuselage components in preparation for painting, including the rear seat back. Primed the fiberglass RCP seat top piece.
5. Dremeled notches in the back of the side and main panels to accommodate the switch anti-rotation washers. [No photo]

  Jul 08, 2020     Panel details; painting prep - (3 hours)       Category: Instrument Panel

1. Removed instrument panel and side panels from the airplane and began prepping the switch holes for the anti-rotation washers. Marked all areas to be Dremeled.
2. Disassembled the avionics racks from the main panel in preparation for painting.
3. Sanded and primed more cockpit panels, including the RCP foot-well floor panels and the front baggage panels.
4. Updated Main bus diagram.

  Jun 24, 2020     Instrument panel side supports - (3.9 hours)       Category: Instrument Panel

1. Cut left side support to rough shape. Progressively trimmed it optimum shape. Sanded and polished edges. Marked and drilled screw holes. Test-fit the support to verify it's the right profile.
2. Traced and replicated the part for the right side.
3. Installed supports on racks, then installed panel into the airplane.
4. Cut and polished two 1" attach angles. Pre-drilled #19 holes, then used these holes to back-drill into the aircraft's upper Z-channel. (I had to make a crazy assembly of two 90-degree right angle drills to do it.) Clecoed the angles in place. These will get screwed into position on the channel. Much later, the side supports will get drilled and screwed into place to the angles (after the top skin is test-fitted).

  Jun 23, 2020     Instrument panel racks; EFIS attach ring - (2.2 hours)       Category: Instrument Panel

1. Riveted on the nutplate ring for the EFIS screen.
2. Spent a lot of time tweaking the attach holes for the three avionics racks behind the panel, in order to get the boxes to line up just right. It's important to get these perfect, because I will be fixing them in position with the side supports shortly.

  Jun 21, 2020     Instrument panel racks; EFIS attach ring - (2.5 hours)       Category: Instrument Panel

1. Drilled the rivet holes for the EFIS attach ring.
2. Drilled and grommeted some new holes for wiring to pass through the gear tower.
3. Continued fabricating the side pieces for the instrument panel avionics racks.

  Jun 20, 2020     Panel avionics rack; throttle grip - (2.3 hours)       Category: Instrument Panel

1. Removed throttle grip and replaced it with a new, improved one with a better feel and look. The new one is the same shape and size as the previous one, but it has a smooth finish and looks really professional. Put 4 layers of marine heat-shrink on the switch wires where they pass trough the slider slot.
2. Began mocking up the side supports for the instrument panel avionics racks out of cardboard.

  Jun 19, 2020     Avionics and LRU shelf test fit - (1.6 hours)       Category: Instrument Panel

1. Fit most large/deep avionics to panel and installed it in the airplane.
2. Installed the avionics LRU rack behind the panel and checked all clearances.The back of the G-meter was slightly closer to the rack than I had anticipated, but it will work fine.
3. Checked position of all wire bundle runs behind the panel to make sure everything clears.

  Jun 18, 2020     Avionics test-mount - (1.6 hours)       Category: Instrument Panel

1. Finished installing all three mounting racks for the avionics.
2. Installed the avionics to check their alignment, clearance issues, etc.

  Jun 17, 2020     Avionics rack - construction - (2.2 hours)       Category: Instrument Panel

1. Riveted side angle pieces to back of instrument panel.
2. Fitted Garmin racks for GTN 650, GMC 507 and GMA 245. Aligned them using the actual unit bezels as a guide. Clamped the racks in place, marked the angles for holes, centerpunched and drilled the mounting holes. Test-fit the audio panel rack with #6 screws.

  Jun 16, 2020     Instrument panel - version 3 - (1.7 hours)       Category: Instrument Panel

1. Took delivery of my newest version of the instrument panel, after some slight discrepancies were found on the previous one. Live and learn.
2. Deburred all panel holes and edges.
3. Drilled and clecoed avionics rack attach angles onto the panel.
4. Countersunk all the rivet holes.

  Jun 05, 2020     Avionics racks - construction - (3.1 hours)       Category: Instrument Panel

1. Installed instrument panel, fit all avionics racks and checked depth and clearance issues. Decided to move GTN650 up one space. (It will fit at the bottom, but the middle location will ease several wiring issues, and will will also make the 650 screen easier to see.)
2. Removed racks and safety-wired them together to make the process of drilling them in place easier.
3. Did miscellaneous other wiring in forward fuselage, including pitot heat.

  Jun 04, 2020     Panel stand; avionics rack angle supports - (2.9 hours)       Category: Instrument Panel

1. Built a vertical support for the instrument panel out of scrap 1x4s that will make the process of assembling the panel (and especially the avionics rack) easier.
2. Positioned, drilled and countersunk the holes that will attach the side support angles for the avionics racks.

  Jun 01, 2020     Side panel revisions; switch panel tab holes; diagram revisions - (2.1 hours) Category: Instrument Panel

(No photos today).

1. Made some final labeling revisions on the side panels.
2. Drilled 1/32" deep slots for the anti-rotation washers on the right-side switch panel.
3. Made some revisions on the electrical schematics, especially the Essential Bus.
4. Re-routed the wires for the flap switch so they deconflict with the switch itself.

  May 31, 2020     Right side switch panel - (3 hours)       Category: Instrument Panel

1. Printed and trimmed my full-size hole template to the right switch panel. Verified all measurements.
2. Center-punched and drilled all six switch holes, plus the four holes for the switch guards. Test-fit the switch guard and the accompanying switch.
3. Riveted all stiffeners to the back of the switch panel.
4. Riveted all nutplates to the stiffeners.

  May 18, 2020     Panel avionics rack; side panel holes - (4.2 hours)       Category: Instrument Panel

1. Finished fabricating the side angles that will support the front of the main panel avionics racks.
2. Fitted the racks to check clearances.
3. Notched part of the subpanel edge to allow for one of the dimmers.
4. Cut all holes in both the left and right side panels. (The hole for the vent eyeball will still have to be enlarged up to 2" diameter.)

  May 17, 2020     Ail. trim servo connection; Avionics rack (main panel) - (3.4 hours)       Category: Instrument Panel

1. Attached a mini-jack pigtail to the existing airframe wires, to connect the aileron trim servo. The plug and jack have reversible polarity so I can swap them around if I need to later.
2. Fabricated two pairs of copper bus bars for the Main Bus circuit breakers (no photo).
3. Cut and filed notches in the main panel support structure at the four locations where clearance is an issue with various avionics items. Also removed one nutplate and replaced it with a stubby nutplate, oriented 90 degrees to the original one, This will allow the EFIS screen to be mounted.
4. Fabricated one of the two attach angles that will support the main panel avionics. Began fabricating the second one. I had to notch out the edge of the left side sub-panel to make everything work.

  May 14, 2020     Panel initial assembly; Circuit Breaker panel - (3 hours)       Category: Instrument Panel

1. Installed all switches, racks and miscellaneous items. Decided to revise some of the panel details, so the panel will be re-cut shortly.
2. Began re-wiring the alternator controllers, after discovering that the manufacturer has revised their wire-gauge callouts recently -- from 20 AWG to 18 AWG.
3. Began designing the avionics rack that will hold the autopilot controller, audio panel and GTN650.
4. Used a Dremel engraver bit to slot the back of the circuit breaker panel for the anti-rotation washers. Because the C/B panel is pretty thin, I ground off a flat spot on some 7/16 thin washers to go between the anti-rotation washers and the panel.
4. Installed a row of circuit breakers on the C/B panel so I can cut the bus bar pieces that will connect them.

  May 13, 2020     Panel initial assembly - (5.2 hours)       Category: Instrument Panel

1. Took delivery of my main panel and circuit breaker panel, which were cut by a local waterjet cutting company. They did a great job, I noticed that, in the design phase, an error had crept into the dimensions of the hole for my analog timer. Luckily, it's an undersize hole rather than an oversize one, so I can fix it with a file.
2. Filed the undersize hole to its proper dimensions, and enlarged all the screw holes to a clearance-fit.
3. Began fitting various components to the panel to check clearances and fit.
4. Positioned the racks for the GTN 650 and the GMA 245 audio panel, with a thick washer between them. Inserted the units, aligned the bezel depths, then taped the racks together to hold them in place. Taped the pair of racks to the panel and did a test-fit in the airplane, just to check (one more time!) that the GTN 650 will fit above the Z-brace behind the panel. As I knew it would, the rear fan on the radio will pretty much rest on the Z-brace. So everything looks good.
5. Marked the C/B panel for routing out the shallow slots for the anti-rotation washers that will go on the circuit breakers. (No photo).
6. Test-fit the USB charger and 12V port on the C/B panel.

  Apr 03, 2020     Side panel layout - (2.5 hours)       Category: Instrument Panel

1. Laid out all components on the lower switch panels, and checked the clearances and ergonomic issues for each. On the left panel will be the fuel selector, carbon monoxide detector, and front seat heat switch. On the right side will be the circuit breakers for the Main and Essential buses, the USB charger ports, the 12V main battery charging port, and the USB port power switch.

2. I also checked a few clearances on the side panels, and discovered that the magneto switches have to be moved apart just a bit, because of the NASA-style switch guards I'll be using.

3. Figured out where the switches will be on the right lower panel.

  Mar 29, 2020     instrument panel clearances and measurements; C/B panel - (4.7 hours)       Category: Instrument Panel

1. and 2. Installed glareshield and top skin in order to get true measurements of the space behind the panel. (Installing the skin was necessary because it actually pulls the avionics bulkhead forward another 1/2". This gives me an honest 12" of space for the GTN650, which means it will fit just fine). Worked with my CAD guy, Joe, and we moved a few things around on the panel design to optimize the space we have available. 3. Fabricated a new right cabin cover (which will be my circuit breaker panel) out of 0.040" stock. The thinner, stock one just seemed too flimsy to use for a bank of 20 circuit breakers, USB ports, etc.. 4. Marked the panel with some dimensions that will help Joe draw a 1:1 template so I can check the ergonomics and clearance issues.

  Mar 27, 2020     Panel mockup - (1.7 hours)       Category: Instrument Panel

Created a mockup panel out of foam-board so I can check clearances behind the panel and plan where all the Garmin LRU boxes will go. As I noticed a while ago, the .PDF panel file supplied by Vans Aircraft has the panel about 1" taller than it is in reality. So I need to make sure my proposed layout will allow everything to fit. My foam cutout does not include some of the items that I'm sure will clear.

  Jan 29, 2015     Panel mockup; Switch panel template - (5.7 hours)       Category: Instrument Panel

With my new full-sized template in hand, I decided to cut a test instrument panel so I can do some trial fitting of my avionics. This can be critical in the RV-8 because of a cross-brace that limits the available depth in one particular location.

I taped the template to a piece of 1/4" foam-core art board, then manually cut out all the holes. I'll begin test-fitting the actual avionics boxes inside the airplane shortly. The foam-core is not strong enough to do all them simultaneously, so I'll do them one at a time.

I spent the rest of my evening creating a full-size template for my right-side switch panel. This panel is a bit of an odd shape, so careful measurement was required. Also, there are some underlying support angles that had to be accounted for, and some line-of-sight issues for the labeling. Photo 3 shows what I came up with. Once I test the template in the airplane, I'll finalize this layout. (The "Start Arm" switch is lower than the other two on the top row because of a flip-up switch guard that is fitted over it. Visually, it lines up with the others when the guard is closed.)

[Some items superseded.]

  Jan 18, 2015     Fuel selector panel (mid-cabin cover) - (1.8 hours)       Category: Instrument Panel

I never liked the 0.020"-thick mid-cabin cover where the fuel selector and GRT EIS unit will go -- it, like its right-side cousin, was too floppy for my liking, especially since there will be cockpit controls mounted on them. I cut out a 0.040" blank for the left one a while ago, and today, I cut out all the holes in it. I still need to do the slight bend at the trailing edge.

[Superseded.]

  Jan 13, 2015     Panel design - (12.50 hours)       Category: Instrument Panel

This entry represents about a week of work on the panel design, and some updates. Several items have changed: The Garmin 430W has been replaced with an Avidyne IFD440 Com/Nav/GPS, and the Aerospace Logic volt-ammeter has been updated with their latest version, which displays loadmeters for both alternators at once (also eliminating a panel-mounted switch to select between them!) I also moved all the round-dial units into a nice group on the right side, and moved the trasnponder back over to the left side. This made room for the dimmer knobs to be located vertically, out of the way of my right knee when I'm climbing in. I think this is a very pleasing layout.

I still wish I could get the vent moved to the left panel, but switches make more sense there. It's better than reaching cross-cockpit for the commonly-used stuff. But it also means I am going to have to thread a 3" scat tube in and amongst all the panel wiring somehow.

  Nov 18, 2014     Re-fabricated lower side panels - (1.0 hour)       Category: Instrument Panel

Today, I spent some time final-trimming and sanding the new "mid-cabin cover" panels (holding the fuel selector on the left and the circuit breakers on the right) out of 0.040" sheet. These will be much more robust than the stock panels, which are made of 0.020."

The new panels will be water-jet cut to ensure they are very precise.

  Nov 08, 2011     Panel layout work - (1.9 hours) Category: Instrument Panel

I actually did a little more work on the project! In preparation for cutting the instrument panel, I laid out the full-size instrument/avionics templates on the panel blank. My thanks to Bill at Up North Aviation, Inc. for providing accurate layout information for the RV-8.

  Jul 11, 2009     Cockpit / panel planning - (3.9 hours)       Category: Instrument Panel

Today, I temporarily attached the instrument panel, throttle quadrant, flap switch console, map pockets, mid cabin covers, and avionics access door -- all in an effort to finalize the position of some key components. Among other things, I discovered that the smoke-system arming switch will not work where I had planned it on the instrument panel. The switch-guard will interfere with the forward upper longeron. I resolved some other minor issues, too.

I also temporarily attached the right brake line so I could determine a good location for mounting the Approach FastStack avionics hub on the back of the nearby bulkhead. It appears the right side of the bulkhead will work best, and I'll mount it as high up as I can.

I also laid out paper images of the major instruments to finalize everything. I've made several changes in the past six months, based on the lengths and sizes of some components. For example, I wrongly assumed the GTX-330 transponder was the same depth as the GTX-327. The 330 is WAY deeper -- in fact, at 11.25", it's the longest item on the panel, and now becomes the limiting factor for the rest of the panel. In the RV-8, the upper gear tower z-channel cross-brace limits the usable depth enough that you usually have to place a typical Garmin stack as high as possible.

I also moved the ELT remote monitor and several circuit breakers off the main instrument panel.

  Jun 07, 2008     EIS mounting hole; Misc. - (1.1 hours)       Category: Instrument Panel

I located an accurate set of measurements for the Grand Rapids Technologies EIS unit, so I cut out the rectangular hole and four mounting holes in the left cockpit side cover.

[Superseded.]

  Jan 09, 2008     Annunciator panel - (2.0 hours)       Category: Instrument Panel

I completed the labeling for the annunciator lights and attached them to the prototype mounting plate to see how they look. The answer is: Pretty nice!

I think, though, that I'll have to align some of the labels a little more carefully. I didn't notice until I looked at the photo that at least three of the legends have some minor centering issues.

I will also have to cut the holes with a CNC mill or something, because it's really hard to hand-drill nine holes in perfect alignment.

  Jan 08, 2008     Annunciator panel - (3.5 hours)       Category: Instrument Panel

Lots of great progress on my new annunciator panel design. I cut and drilled a piece of 0.063" aluminum as a prototype mounting plate for the LED light assemblies, including holes at the corners for the #6 screws that will attach it to the instrument panel. If this layout scheme turns out to be an aesthetic success, I'll cut the final version with a CNC mill so all the holes are perfectly in line.

I also created the printed legends that will fit inside the light assemblies. I used Avery Clear labels, printed in Bold 10pt "Franklin Gothic Demi" font. (I originally tried "Arial Narrow," which fits and looks nicer, but the weight of the characters was a bit weak, which made the labels a bit harder to read.)

I also researched ways to dim the entire annunciator panel using a potentiometer on the ground side of the lights. I'll test this method sometime soon.

  Apr 04, 2007     Annunciator panel - (.6 hour)       Category: Instrument Panel

Created test labels for the annunciator panel using an Avery clear label kit. I found that the easiest font for me to read from two feet away (normal viewing distance) is Franklin Gothic Demi, all capitals, 15-point size. We'll see how it looks once I print it on a colored label and backlight it with a white LED.

  Mar 19, 2007     Annunciator panel v.1 - (.7 hour)       Category: Instrument Panel

Filed off edges of dividers where they were slightly extending beyond the inner (rear) channel. Painted inside of LED compartments white. Installed LED holders and LEDs.

  Feb 22, 2007     Annunciator panel v.1 - (1.8 hours)       Category: Instrument Panel

Here are some photos of the process of cutting out the two windows in the front channel.

Photo 1: For the front channel, I drilled holes and connected them with a hacksaw.
Photo 2: The front channel, with one of the two "windows" cut out.

  Feb 21, 2007     Annunciator panel v.1 - (2.6 hours)       Category: Instrument Panel

Began construction of my scratch-built annunciator panel. Cut both aluminum channels to length (8.25"). Cut nine slots in smaller channel for dividers, then filed and sanded all edges. Measured and cut nine dividers from 0.040 stock. Used hot-glue gun to fasten dividers into slots in small channel. (The hot-glue gun worked OK, but I'll explore other options later.)

I cut two large openings in large channel. Began with drilled holes, then enlarged them with larger drill bits, then hacksaw, then files. Finished holes with needle files and sandpaper. (Note: The center two sections are slightly wider than all the others. This is to account for the 3/16" width of the center "post" in the front channel that will separate the two windows.)

I also cut a test-piece of thin Lexan sheet for the light cover. The stuff I'm using is very thin, and cracks easily. I might try cutting up a sheet of acetate instead.

  Sep 18, 2006     Panel design and product sourcing - (3.3 hours)       Category: Instrument Panel

Came up with another possible design for the instrument panel, based on the Advanced Flight Systems AF-3400 EFIS/Engine displays, with a Dynon D-10A as a replacement for all the "steam" backup gauges. With the AFS system, cost- and space-savings can be realized by eliminating the VOR/LOC head, the fuel gauges, trim indicators, and several other items. In addition, the AFS EFIS is slightly narrower than the Dynon D-100, allowing side-by-side placement of two screens, in addition to the Garmin NAV/COM/GPS stack.

Ordered Duckworks HID landing/taxi light system.

  Jul 21, 2006     Panel planning       Category: Instrument Panel

(4.5 hours) Used trial version of ePanelBuilder to create this panel. Will explore all options at Oshkosh next week. Might not need "steam-gauge" Tach and MP, but I do like an analog presentation for RPM. Included a small Turn Coordinator and ball below the steam gauge Airspeed, a Vertical Card Compass off to the side, and a standard Altimeter and VSI. This is so that if lightning were to strike the A/C and knock the displays out (worst case scenario in a glass-cockpit airplane), I could still fly the airplane. A LOC/GS is located basically centered below the EFIS PFD because I'll be using it to fly instrument approaches, and having it off to the side makes for a harder scan. Blank area might be used for a few switches, backup engine gauges, iPod, Garmin 396, or something else useful.