panel replacement

[sonex892.]

I flew last Saturday then started ripping the panel apart last Sunday. A lot of work to squeeze in an ipad, maybe add a glove box and tidy up the wiring but I'm well and truly committed now.

The wiring and had become a rats nest after the odd change here and there during the last 9 years. The new panel will hinge down after removing a bunch of screws. The wiring will at least be easily accessible from now on.

[GordonTurner]

Ok. That’s completely AWESOME!!!! I have been envisioning in my mind how to make the panel more vertical, larger, and rounded, and how to tie that into a glareshield that followed the curve of the windscreen instead of the angles of the tank.

What material are you using for the glareshield and do you have any shots of the structure that supports it?

Thanks, Gordon

[sonex892.]

Hi Gordon
The glare shield is 6061 .025. I was originally thinking fibreglass. Purely because it was easier I went with the aluminium. Then I weighed it, 1 kg ouch! Now thinking of using the aluminium one as a mould and going back to glass. I'd like to be able to halve its weight. Really wish I had some carbon fibre in the shed.
I plan on gluing angle supports in to support the sides of the glareshield using automotive double sided tape. I'll take some more photos in the coming days

[peter anson]

Hi Steve, is the new curved glare shield a dummy over the original glare shield? If that's the case, you can get 2024-T3 sheet down to 0.016" thick which would save a bit of weight and also lighten your wallet. The pull-out panel is definitely worth it.
Peter

[sonex892.]

Hi Peter. Good idea with the .016 Yes the glare shield is only a dummy.

[GordonTurner]

I remember there was a talented Australian some years ago who made a similar and very attractive glare shield modification. The material was some kind of automotive interior plastic designed for the UV environment. Not sure if plastic would be lighter than thin aluminum though.

Gordon

[ihab]

I wonder if you could make the glareshield extension out of fabric, and just have that go forward all the way to the edge of your panel making it a single smooth surface. It would be quite lightweight.

Ihab

[sonex892.]

Got the panel riveted in a glove box done and a fibreglass glare shield. The glare shield is 2 layers of 6oz mat and strips of core mat to stiffen it weighs about 650 grams which is still weight, but better than 1kg.



Glare shield fixing is .025 bent angle held down to the original glare shield with 3M automotive double sided tape and 3mm rivnuts for the fibreglass

Just need to add carpet or paint? Tidy up the wiring and do an annual

[Mikegaydos]

Wow!

This is a very useful mod. I’ve always believed the dash space could be better.

I was curious if the original tank cover could be omitted on a new build with this kind of mod? It would help negate the weight tradeoff.

I get my fuse, wings and plans in Oct but this stands out to me as a mod i’d like to do.

Nice work!

M

[GordonTurner]

Deleting the original glare shield came up once before. Sonex factory answer was NO because it is a critical part of securing the fuel tank.

Lightening holes you would probably be ok with though.