Monthly Archives: June 2021

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Instrument Panel (5)

With the fuselage now initially primed, the installation of the instrument panel could begin.  As many connections as possible were first completed before insertion of the panel.

PREPARATIONS

Here the GTX45R remote transponder / ELT brackets were installed behind the baggage bulkhead.  Termination of the major NAV/COM antennas with BNC or TNC connections behind the front sub-panel was also done.

 

 

ANL fuse and ammeter shunts were installed on the firewall side by Rich. The remote Airwolf oil filter bracket was bolted into place.  Inside, the forward cabin heating tube was attached in the center tunnel.  Many other items were added to the cockpit-side of the firewall – cross-tie contactor, ground blocks, GAD29 ARINC adapter, GEA24 engine monitor…

 

 

Initial wiring for B+C LR3C voltage regulators, VPX-PRO electronic circuit breakers, Guardian CO detector, floor lights, panel fans, etc. all were set to final configuration where possible.  The instrument panel was repacked in the original shipping crate for migration from my basement to the workshop for installation.

 

 

INSTALL

Rich and Tal unbox the instrument panel from the shipping crate, then hand to me for positioning under the dashboard.  Notice the PFD and MFD were removed to save weigh and allow easier access during installation.

 

 

 

Job done on the basic installation.  I had expected a tougher battle getting everything aligned, but was pleasantly surprised how well the panel fit on the first try.  In retrospect this was probably due to the time/effort/diligence applied to the mock-up and bench testing previous done in the basement workshop.

 

 

FURTHER CONFIGURATION AND INITIAL TESTING

With the panel now fastened in place, final attachment of wire bundles to VPX-Pro, voltage regulators, avionic stack, ground blocks, fuse holder… could occur.

 

 

Here was the first power-on testing performed with the panel inside the fuselage. Checks on basic functions were good, but a few tweeks were needed for control stick inputs, autopilot servos and trim motors.  All of these turned out to be simple repositioning of DSUB connector pins.

 

 

The G3X configuration pages show most of the main equipment details in their responses to CANBUS signals.  A few items have not yet been connected, so further testing will be performed as these devices are brought online.

 

 

Thumbs up on the radio COM1 and COM2 checks!  Now on to pulling and terminating more wire through the side cable chases.

 

Prime/Paint (2)

Completion of body work and initial priming of the fuselage with DesoPrime CF took many weeks to accomplish.

The frame around the baggage door was just one example where the height difference between parts was leveled and smoothed.  After scuffing the raw aluminum surface and degreasing thoroughly, a mixture of West Marine resin/colloidal silica was applied to provide a hard substrate for later Superfil covering.  Multiple layers and many hours of sanding ensued to get the final result.

 

 

The treatment for just aluminum surfaces was scuff, degrease, apply Prekote, then prime.  The fuselage top was primed in a separate sequence than the bottom. (more on that later).

 

 

 

Before and after shots of the fuselage from the rear. The left photo shows filler transitions on the rear window, door openings, rear air scoop, and canopy/skin seams.

 

 

 

Before and after shot of the fuselage from the front.  The left photo shows body work around the windscreen base, door openings, forward air scoop and upper/side fuselage skin seams.

 

 

 

After the first prime on the upper fuselage, additional filler and smoothing was needed in a few places.  Particular improvements were applied for the windscreen base – where the transition to aluminum to the fiberglass base needed attention. The left photo shows the sanded elements ready for a second primer round.  The fuselage was then lifted about 6″ to provide more room to spray the bottom.

 

Having never painted upside-down before, applying primer to the bottom was a real challenge.  It took a few days of preparation before the painting session.  The results seemed fine, but later sanding will reveal whether the primer thickness is uniform across the surface.ad

 

 

 

MISCELLANEOUS

Custom elements were made prior to installation of the instrument panel and wiring harness.  The left photo shows 1/4″ connection tabs made into ground blocks for the wing roots and tail section.  The right photos shows brackets to hold cable bundles under the Aerosport kick panels near the rudder pedals.  These were needed as the default Vans brackets were too ‘proud’ (too high to fit under the plastic panels).

 

On the left is the SEM primed bracket with 2 AWG cables for PRI BATT and SEC BATT running from behind the baggage area to the firewall.  The kick panel was rough fit for the dummy instrument panel.  Later adjustments will be made when the real panel is installed.