Bob and Karen Brown's Airplane Building Project


 
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THE PANEL
(AND SUBPANEL)

 		 Sometimes, Karen has to remind Bob that it's ok if the rivets aren't flush style, or there is an extra hole...it's the SUBpanel!  Of course, there have been tours of the industrial section of Salem to find some place that sells exactly the right screw for the panel, so it will look real sharp!  (Cascade Nut and Bolt, on Vista, has every one you would ever need!  And they will sell them in small lots too.)  (Click any picture for a larger view with an explanation.)
Sub Panel to left, firewall to right. Sub Panel The Virgin Panel set into place. The panel...some assembly required.  This was wired by Pacific Coast Avionics.  Cardboard Panel
We cut two cardboard panels out of some heavy stock we had laying around.  Karen and I both sat in both sides of the cockpit and messed around (not like that!) moving instruments and radios around until we found a layout that was acceptable to both of us.  I'll warn you now, that while you are building, there will always be something new you think you need.  Think long and hard about what that will mean to you in the way of extra work.  That's the voice of experience. Laying Out the Panel

1 inch gridlines were drawn on the panel using a sharpie pen.  The biggest hole layouts were placed first based on measurements from the cardboard template.  Spacing of the holes for instruments and switches were accomplished next.  I can't emphasize enough to take your time and go slow.  A well layed out panel that is straight and squared up looks good and normal and right.  One switch hole out of place can make the hole thing look like crap...you'll always notice it quickly.

 Using a square to position the instrument mounting screw template.  Holes for 3 1/8" and 2 1/4" instruments were done using an instrument hole punch tool.  You drill small holes, literally...start with #40 bit to get your centering perfect.  Drill them bigger and bigger until you can get a Unibit in there, then drill to 5/8" to insert the instrument hole punch.  Get your 1/2" ratchet out and start cutting.  When the cutout tool has gone about halfway, loosen the tool and rotate it 90° before completing the hole.  That reduces the possibility of bending the edges of the cutout.  The template for Drilling Mounting Holes for Instruments Cutouts for the radio stack and engine monitor were made using a dremel tool with a fiber reinforced cutoff wheel.  I layed several layers of tape right up to the cut line to give myself some breathing room.  Edges were finished using files and then polished using sandpaper and finally scotchbrite pads. First work on building the rack for the avionics trays. 
Cuts in Sub Panel for Radio Stack

The ICOM A-200 radios extended past the subpanel, so I had to cut out this area and build a truss to support the back of the radios.

 Extending Hole Pattern for Upper Subpanel Support Using Rivet Fan to Extend Line.  Notice hinge riveted on to subpanel at upper left.  This is the hinge that the main electrical bus is attached to. Support Bar for Upper Edge of Radio Cutout in Subpanel More Tray and Bracket Work

This was a very iterative process, yet one I took extra time to fit well.
Truss for Tray Support

This is a piece of .063 angle that is riveted across the subpanel cutout.

 Final Fitting of Trays Rear View of Subpanel Support Brackets

Battery bus is visible in upper left of picture

 Panel and Subpanel In Place After Subpanel Supports Installed View of avionics trays with main electrical bus in lower foreground.  Thats the E-Bus to the right.
Fitting the tray for the KMD 150 GPS Working on attaching the KMD 150 Mounting tray.   Spacers for KMD 150 Mounting tray   KMD 150 Mounted in the Panel Template for ACS 2002

This thing is a precision cut piece of steel with corner holes predrilled, along with the lines precut along the edges.  You just lay it out squarely on the panel and drill it to the panel, then, while it's cleco'd in place, you use a cutoff wheel in the Dremel tool to cut the lines.  The corners were then radiused with files.
Trying the screws into the ACS 2002 mounting holes The ACS 2002 Fits! ACS 2002 in its hole! Close fit of the ACS 2002 engine monitor display First Look at Panel with Instruments
Back Side of Autopilot and Airspeed Indicator Initial Cut for Trim and ELT Switches   Cutouts Complete for ELT and Trim Switches ELT Switch, Mounted Behind Panel, Recessed Electrical Switches Installed in the Panel
Electrical Switches

These were laid out in a horizontal fashion instead of vertically, because I didn't take the time to measure them closely enough before we made preliminary cutouts in the panel.  Dan Checkoway was on the right track in extending his panel slightly downward.

 Test Wiring a 2—10 Switch Twelve Volt Power Plug is on the right side of the panel.  This area will be used to mount the latest handheld (??) using a RAM mount. Instrument Panel Mounting Brackets Air Vent 
 
Here, the Angle of Attack display is visible.  The black and red buttons are the control buttons for the AOA.  AOA power switch is the white toggle between them. Left side of panel Left side of panel On the left is a piece of .040 aluminum sheet, on the right is the headset jack bracket I made from a similar sheet.  These are mounted on either side of the subpanel.  
 
View of the left side of the panel, prior to installation of Angle of Attack instrument Service loop of sensor wiring to ACS2002 engine monitor analog box.  This service loop allows the analog box to be removed and lowered without removing wiring.  I am hoping this will make me happy at some point... This view of the right side of the panel shows the cutout where the radio stacks and engine monitor will be installed. Wiring to ignitions is visible in lower right.  Square instrument is Trutrack autopilot, with the Altrak wiring just to the right of it.  

Last edited 13-Jan-2006