INSTRUMENT PANEL

DESIGN PHASE

I'm on the third major iteration on the panel.  The technology in avionics now changes like computer technology; and what you did 3 years ago is obsolete.  The original panel design used the standard round gauges and gyros for the flight instruments, with the state-of-the-art GPS and moving map display.  I did all the panel layout work on the computer with PanelPlanner software. The estimated weight was about 44 lbs.

With the decrease in price and increase in features in Electronic Flight Instrumentation Systems (EFIS), it now seems to make more sense to take that route, as it is the way of the future.  The second panel layout is shown below.

After further review, I decided there was still a better way and better value, and revised the design once again.   It uses a dual screen Grand Rapids Technologies Horizon I EFIS.

 The one that I  actually built is shown below.

CONSTRUCTION PHASE

In preparing to build up the panel, I first wanted to both strengthen the panel and provide a more true back surface for mounting the instruments.  I sanded the back with a sanding block to get it flat, and then applied three plys of fine BID. This gave a flat, strong panel that was almost exactly 1/8" thick.

I next got things all laid out on the panel, and began cutting and drilling holes; always measuring twice (or more) and cutting once.  Completing the panel structure required adding a framework for mounting of the avionics trays.  I took a little different approach and mounted a 1/4" x 1" aluminum bar on the left side of the stack, and a 1/8" aluminum on the right.  The one on the left was first mounted to the panel with three countersunk screws threaded into tapped holes in the edge of the bar.  The left side is mounted against the back step with three screws.

After marking, drilling and tapping the holes for the #6 screw used to anchor the trays; these bars were microglassed and screwed into place with alphapoxy and milled fiber.  I used a slightly smaller bit to drill out any microglass that got into the tray mouning holes; and drilled right on through the panel; then tapped all the way through the aluminum and fiberglass.  With the 5/16" #6 screws in place, I could then come back and fill the holes on the front side of the set-back.

With the mounting frame in place, I then cut the opening for the avionics flush against the frame, trued things up, and trial mounted the trays.  The trays also need support in the rear with brackets on both sides, one of which attaches to a bracket that is screwed and microglassed to the fuselage. When all was right, the trays were removed for painting of the panel. 

Then it was just a matter of getting all the things mounted and wired up.  A huge job actually.  EFIS and electronic digital everthing makes for a lot of wires.  The good news is that it provides a tremendous amount of well displayed information; and the panel weight is only 23 lbs., including the CD player.