Instrument Panel: Fit-Up

It's amazing how much cumulative time I've spent on this instrument panel over the last couple years. It first began conceptually with which instruments to outfit the plane with and then entailed laying out the configuration, which I repeatedly changed using a panel design software program. More recently, I cut out scaled cardboard cutouts and placed them on the panel. I would sit in the front seat and pretend I was manipulating them in flight and, likewise, move things around until everything felt and looked right.

Next, I accumulated everything that I would mount on the panel and take measurements and check for clearance behind the panel with other instruments and just as important with the structure.
After laying out the linework, for rectangular openings I would drill holes in each corner and scribe inner lines where I would cut the metal with dremel cut-off wheels. Here is stepwise procedure I used for the turn coordinator.




Next, I would file the opening to the final cut-out lines.



For the smaller holes, I would drill out with a step drill bit. For the larger holes, I used a drill bit with an adjustable hole cutting assembly (not shown).

Here is the completed panel, with all cut-outs complete. I should note that I had constructed a mock up demo panel with my first piece of aluminum.

Reagan continues to want to jump into the cockpit and pretend to be pilot-in-command.

Next, I will drill all of the mount holes for the instruments and then take to Baraga for gray powder coating. Called today for a quote and was told only 10 bucks!

Fuel Lines Install: Fuselage

I installed the fuel lines and fittings in the cockpit area. Starting from the station 3 (aft end of wings) area are the aluminum risers to be tied to fuel tanks in the wings later.

Here are the two aluminum lines from each aft wing manifolding together at the mixing block. The combined flow from both lines runs through the line on the bottom.

Moving forward, here is the aluminum fuel line clamped to the left foot rest board. Note the loom material for anti-chafe at frame wear points.

Here is the aluminum line connecting to a cross fitting and two additional aluminum vertical lines running in from the forward side of the wings.

Here are the vertical lines stubbed off until wings go on. Apparently, must have redundant drain lines coming from fore and aft locations of fuel tanks in case a line plugs.

Here is the cross fitting and the rubber hose line running to a fuel on/off valve and then forward to the firewall.

Finally, here is the terminal end of the fuel line adapting to the firewall fitting. Upon hanging the engine, I will continue from here.

Seat/Shoulder Belt Restraints

I put the seat belts in early so I could get a feel for how they would affect me in trying to manipulate controls on the instrument panel.

Boot Cowl Fit-up Continued: Install fabric

I installed Sunbrella material to the inside of the boot cowl to match the firewall interior. I really like the appearance of the fabric much more than simply painting the fiberglass. I then burned holes through existing hole locations and riveted bottom angle supports and fasteners which will hold the front cowling.

Fill and Bleed Brake System

I used an oil pump bottle with attached hose to fill brake lines from bleed valves on the wheels. Worked slick. Filling from the bottom point resulted in very few bubbles. Got on the brakes and, with my Dad's help bleeding the valves, was able to eliminate the mush and get the brake pedals solid. Tried the brakes out in the garage and they work great. I was pumped (no pun intended) that there were no detected leaks in any of the fittings.

Install Throttle Lever Assembly

Installed throttle assembly. Push-pull tube connects fore and aft levers for redundant control.

Install Brake Lines & Cylinders

After installing the rudder pedals, I installed the brake master cylinders and lines. I had hoped to fill the system, but found I need to use a special kind of aviation brake fluid which won't eat the seals. I have it on order and hope to complete next week.