Dec 14, 2022     Panel prep - (1 hour)       Category: Instrument Panel

More pondering than pounding today. Sanded some clearance off of the lower outside panel edges, as it was dragging slightly on the cage when tipped straight up and down. (It wants to lean forward pretty hard now because of no other support. Most of this support will come from the radio mount plates that will run forward from behind the panel. These plates re provided with extra length and so will need to be trimmed for length. So, to find maximum length the firewall needed to be mounted, which required removing the angle that was fitted to hold the forward rudder return cable pulley. Re-mounted it forward of the firewall and left the pulley off as it will have a different mount bolt when the rear rudder return cable and pulley show up and are installed. Used die grinder to add bolt clearance to a few holes in the firewall. The next step was to cleco the outer top portions of the boot cowl to bothe the firewall and the panel frame so that the correct length for the radio mount brackets could be determined.

  Jan 07, 2023     Panel frame mods / remounting panel - (2 hours)       Category: Instrument Panel

The instrument panel frame had previously been modified to clear the IGN BATT switch on upper left of panel. In the process the frame was cracked and stop drilled previously. It also became apparent that the frame was going to interfere with the mounting of the womack style air vent nozzles and would need to be bent for clearance. Most of the bending was done with the panel still temporarily mounted, however to avoid damage to the frame I undid the panel, pulled the frame and used heat to finish the bending of the inner lip of the frame. I also riveted a doubler to the frame where the tear had occurred previously. The air vent nozzles were then mounted after some enlargement to the holes and a locator notch being added for each side. Finally, the panel frame was riveted into position with SS Rivets and the panel re-mounted, this time with all of the rubber grommets.

  Jan 12, 2023     Drilled subpanel for control cables - (1 hour)       Category: Instrument Panel

I have a subpanel of machined aluminum manufactured by Steinair when they did my panel. It had pilot holes for the throttle, mixture, park brake and cabin heat. First step was to fit the subpanel to mount to the panel frame under the middle of the main panel. This will use 3 #8 screws with nuts on top of the panel frame. Next step was to drill out the control cable mount holes to the proper sizes, (.75" for throttle and mixture, and 3/8" for park brake and cabin heat.

  Feb 12, 2023     Fire Extinguisher bracket - (1.5 hours)       Category: Instrument Panel

Have been contemplating a way to add the factory throttle cable bracket support (to be able to mount a fire extinguisher under it) for quite some time. I have a heavier machined bracket that Steinair did with my panel so things were different and even among factory planes it appears things aren't always done the same. I also want a way to support some of the weight of the wiring harness behind the panel and I think this will give me something to do that plus add some rigidity to the overall panel assembly. I will use the factory support bracket and the two side brackets. The side brackets will be cut to 12” and be screwed through the panel on the end with the bent angle and I will support the forward portion with an adel clamp and angle aluminum off of the cross tube behind the panel. Using some short #8 countersunk screws and nut plates on the bracket to attach to both the throttle / mixture cable housing and the two side brackets. Didn't get done but do have a good idea of where I'm going finally.