Daily Archives: 21/05/2019

Instrument Panel, Panel

Tuesday 21st May 2019

Leave a comment

Music: Soul Classics 1970-1975, Embrace

I have the Garmin G5, Airmaster prop controller, Flap switch and the Dynon sub panels to do today. The sub panels cut outs aren’t just rectangles so I need take my time and as they say measure twice and cut once. In reality I think I’m measuring 4 or 5 times and cutting once which is taking some time but it’s got to be right otherwise it’ll spoil the look of the cockpit.

The G5 and prop controller need 79mm and 57mm holes so these are needed to get a neat hole.
I’ve finally decided on the layout. This look like the best option with the panels that I need to install. I’ve also borrowed an ignition switch from Ian to position on the panel before my one is delivered.
Marking up the panel for the prop control hole, making sure that its equidistant between the G5 and the flap control. These are the easy holes to cut as they are circular and along a single line.
This is the template that Dynon supply with their panels. This template is used for the 3 of the 4 cut outs.
I’ve thought of different ways to cut the holes out. Jigsaw, Fretsaw and drill. Although I have very fine blades the jigsaw snagged when I used it on the main panel cut outs and I don’t have a jigsaw so small holes are drilled around the outline. Once drilled the material between the holes is cut with a Stanley knife.
Once cut out fine adjustments are made with a file. The audio panel cutout at the bottom in this pic is the only one that’s a rectangle which made it easier but the template seemed to be too large so it’s lucky I measured the unit before I cut the hole!
The first controller panel installed to test.
The last job for today is to drill the hole for the flap controller and cut the plastic rod for the knob.

Still a little long so another cut needs to be made.
These pictures of the avionics have helped me visualise the panel layout before cutting and can finally be binned now all the holes have been cut.
The instrument panel, with components installed. Quite pleased with it but it’s taken a lot of time decide on the layout and cut. Some more cut outs need to be made for the trim position indicators, Magneto switch and USB power.
A late finish tonight. Looks like I’ve missed a lovely day!