05-02-05

Decided to build a really affordable panel myself with removable sections.  First drilled holes where I wanted to use

the 1" punch tool.

Then I punch the holes with the 1" punch tool.

Then I used my reciprocating air saw to cut out each section.

I'll clean the edges up and plan on making each section from 1/8" ply and then laying up Glass and Carbon Fiber

on them.  I'll have to try a open layup and a wet one to see how I like each look.  I think the open one will look best

and have less glare.

05-05-05

Today I cut out 2 separate panels.

The one on the left will be fitted with flight instruments.

The right will have comm/nav/audio.  I'm laying up Glass on the rear and tomorrow I'll lay Carbon Fiber on the front.

Vacuum bagging is the only way to go.

It will be as smooth as a babies you know...

05-07-05

Laid up the Carbon Fiber today. 

I obviously have a few more instruments to install but you get the picture.

Tell me what you think........BTW those are 6-32 Aluminum Button Head Screws, not rivets.

05-14-05

Layed up a new layout on 3/32" ply just to see if it would "fly" no pun intended.

Here is the right side on 1/8" ply.  I figured since I made a left side in 1/8" I'd go ahead and finish the job.  The real reason

I an laying up a panel on 3/32" is because I found out that the Altimeter doesn't normally go on the far left like I did in the

first panel I made.  I might still use it but I'll decide after I see how the 3/32" one works out.  Here is the right side and you

can see the new one in the background with the holes routed out.

05-15-05

Heres the new panel with the new instruments installed.  I have a Compass and Turn Coordinator on its way.

05-18-05

I got a new Garmin SL-40 from CHIEF AVIONICS for $1320.

and some really neat relays from AIRCRAFT EXTRAS for my Elevator Trim and Aileron Trim that will be adjusted from my stick.

They were $19 each and are small, stackable and easy to mount and wire.

05-19-05

Had to cut a hole in the center bulkhead for the SL-40 to pass through.

05-20-05

Since I had all my Flight Instruments laid out and finally decided on what Avionics are going in this thing, I decided it was time

to add all the plate nuts for attaching both panels.

05-21-05

Here's what it looks like so far.  Not a good picture because of the flash but I like it.

05-22-05

I decided to add the plate nuts to the Radio Tray.  I used 3/16" 6-32 Stainless Steel Bolts to mount them to the side plates.

I first mounted the tray where I wanted it, drilled 1/8" holes where I wanted the plate nuts from the inside out through the side

plates and then removed the tray, enlarged the holes in the tray and installed the plate nuts.

Countersunk the plate nuts.

The tray has enough offset so that the Radio will clear the plate nut and the rivet shop heads shown here.

The screw will be just long enough to be flush with the end of the plate nut shown here.

Plenty of clearance as you can see...

The reason I went this way is because if you use plate nuts on the outside you have to use flat head screws inside the tray.

It was a biotch to install them through the plate nuts with a small Phillips w/o stripping the head out.  As you can see from

this photo I was initially going to do that then changed my mind.

05-24-05

I mounted the Transponder in the same way with the plate nuts. The Transponder has a slot on each side of it to clear the

plate nut and rivets.

05-25-05

Here I finally got my Garmin GTX-320 installed as well using the same method.

I mounted them both so that they are flush with the panel for a cleaner look.

I'll be replacing the 8-32 screws shown here with Black button head screws after I get everything behind the panel painted to

match my interior which should be soon.  Then let the wiring begin!!!!!!!!!!!!  I can't wait to add power to the SL-40 and see

it in person.

I decided where to put my Fuse Panel so I drilled and plate nutted it.

Here's where the cute little Relays are going.

Bam!  Its time to paint the backside of the panel for final assembly... I hope.

05-26-05

Painted the backside of the panels and assembled them hopefully permanently.  I used Black 8-23 button head screws to hold the panels in place.

My Turn Coordinator will be here tomorrow and I'll install the rest of the instruments.

05-27-05

Got a new Electronics International SC-5 Super Clock off Ebay for a good price.

My Falcon Turn Coordinator came today from Aircraft Spruce. So it was time to assemble the panel. Look at all that room

behind the instruments!  How am I gonna fill that up?

Here's what I have so far.  As you can see I mounted the MGL ASI-3 behind the panel and it looks much nicer.

I added power to the ASI-3 to see what it looked like in the panel.

05-28-05

Mr. Jim Andrews came by and gave me a Flightcom 403mc Intercom.  From what I understand the intercom on the SL-40

isn't what it should be.  However this Flightcom Intercom has a input for music and will be muted out and overridden by the

comm when a transmission comes through.  It matches my panel quite well and free is good!

Here's a pic with the switch panel attached.  I have a few more things to add but it is looking sweet...

06-04-05

Added the stiffener for the solenoids.

Added the solenoids and copper strap.

Here the cool connector that comes with the SL-40.  You can disassemble it and solder the core wire to the center pin

with ease.

Heres the other end that will go on the Comm antenna.

06-07-05

I installed my MGL 2 1/4" G-Meter.

Here's a pic of my Electronics International SC-5 Clock running.

06-08-05

I made these blocks to mount my trim and flap relays.  I had these mounted behind the Instrument Panel and decided

to move them so less wires would have to be run.  I am mounting them at the base of the flight stick where the wires

exit the stick for a simpler installation.

I needed them to be angled to be able to get to each wire and screw.  So once again I used Delrin to mount them.

These relays used 9 positive and 9 grounds, 2 switching and 2 output wires to power all 3 controls.  So I made a little

wiring harness to make wiring these things much simpler.

06-13-05

I had to create a nice place for my Headset Jacks so I made a Bezel to hide the ugly Vans vents and a place to put my

Jacks.  It tied into my lower switch panel nicely.

05-14-05

This is the Odyssey Battery box from Spruce that was $22.  Also seen here mounted below the solenoids is a 40 Amp Fuse

for my entire plane.

06-21-05

Decided to go with Vernier Cables instead of the quadrant.  Takes up less space and gives a finer adjustment.  However I have

had advice from others that a Vernier Cable for Throttle is not usually desired and a Friction type is easier to use.  So I'll

get a Friction type Throttle Cable and send this one back.

Notice the MGL Compass  at the top.  Very nice and it has a remote sensor.

This is where I mounted the sensor. Notice the box is level and the sensor is unseen.  I decided to mount it here since

there were no ferrous metals or electrical current that could interfere nearby.  It is powered by one 24 AWG wire and

a regular RCA cable.

My GRAND RAPIDS EIS 4000 finally arrived.  I purchased it through Spruce for $877.  The edges of the faceplate leaves

a little to be desired so I decided to mount it from behind.  I looks a little cleaner to me and notice I got rid of the Fuel Gauge bezels.

07-21-05

I know its been a while since I have updated my site but I have been traveling all over the U.S. for my job and had little time

to work on my plane and update the site.  I have done lots of piddly wiring and cleaning up the layout of wires and still

feel like there is lots to do.  I could write a book on what to do first to make things easier at this point but that too would

take up the little time I have had.

Here is where I added the Aileron trim.  If your plane will have this unit, I highly recommend that it be installed immediately after

your interior is painted and BEFORE any control surface parts installed!

I had to make an entire new mount here because the new friction throttle needs a much smaller hole for its mounting.

I also went to a RED carb heat knob.  I know its placement isn't the norm but that's where I decided to put it even knowing

this.  Nice thing is it is EXPERIMENTAL.

Here's the static and pitot tubing spaghetti as well as ignition switch wiring.

I hadn't posted pics of my grip as of yet. Since I just got the passengers "dummy" grip today I decided it was time

to post pics of them both.  They are CH Products grips.  On the Pilot side I am using the hat for Aileron and Elevator

trim.  The 2 buttons behind the hat are usd for flaps.  The trigger is for Push to Talk.  I still have a small buttion below

the trigger to use for something unknown.  I was hoping use it for "flip-flop" but the SL-40 doesn't have that feature

remote.

The passenger side has PTT trigger and the button below. This grip was $50.

I added the connectors to the wires for the tail and left wing strobe and have yet to get another connector for the right wing

strobe.  I'll pick one up at Frys soon.