N307TW’s Panel is finally done!
Posted: Sat Apr 18, 2020 7:15 pm
After over a year of planning and fabricating the custom panel myself I finally finished my B-Model main panel, and audio panels today. It’s been a relief getting the custom touches completed. Here is some background on the custom panel and for those wanting a bigger EFIS on the B-Model panel, how I did it.
I was told the bottom support couldn’t be cut for structural reasons on the B-Model so I decided to go up instead. I really liked the bigger screen and capability of the Garmin system and didn’t want to compromise.
I first started by cutting into the glareshield, built custom brackets, and built a fiberglass hump and while its not the most aesthetically appealing, it’s quite functional and enabled me to do several things. It allowed me to install a flush mounted compass, it also allowed me to install a float fuel level sender in the top of the fuel tank instead of mounting the standard Sonex capacitance probe from the bottom. That way if it ever needs to be replaced I can easily remove the fiberglass hump and replace it with five screws. The mount the float goes into is permanently bolted and sealed to the tank. All holes in the tank including oops fittings were coated with the 3M ProSeal found most affordably through Vans Aircraft. The hump also allowed me to route the fresh air vents to the top of the panel rather than underneath.
The hump is secured with 3M dual lock industrial Velcro and four plastic fender retainers. I also built out a larger lip to install some red LED lighting for night flights. The larger lip will also block out some sun and prevent glare hopefully. Everything from the panel to the glareshield, lip, and hump is wrapped with carbon fiber vinyl. The switch panels are 1/8” plastic which are painted and then laser etched and backlit with led strips. There’s a built in cup holder that came out of a wrecked Audi that pushes in and out of the panel with the touch of a finger mechanically.
Since I went higher, I designed larger sub panel pieces that are flush riveted to the original panel plate provided by Sonex. The larger panels are made of .050” T6061 to give it more strength as well. The holes for EFIS, Air Ducts and IPad were CNC’d to make it look nicer for installation. Nothing was made removable since the EFIS hole is so large I can get to everything from that hole or from up above with the fiberglass hump removed. The EFIS is the 10.6” Garmin GDU 460 from the G3X platform. There was room to mount the engine monitor (GEA 24) directly behind it. The transponder, radio, ELT, and other assorted equipment were all remote mounted behind the seat in the cargo area. The iPad Mini is mounted using a flush mount by Guardian and there is a USB port behind the panel to give it power. There’s an additional USB power port on right side of panel. The cigarette plug is always powered in case of emergencies or to back feed the battery with a possible solar array in the future.
The entire system is based on automotive fuses but there are many components that utilize Garmin’s vertical power unit (GAD 27). The flaps, manual trim tab (with Ray Allen Servo) and landing lights all run through it. There is also the B&C overvoltage crowbar system integrated in my electrical system as well. The avionics bus has its own fuse panel in the cargo area. The only systems to have circuit breakers are the roll/pitch autopilot servos, flaps, and trim servos. This is in case any one of these components runaway; I can easily pull the power. Garmin states it’s autopilot servos have a clutch system, but it is peace of mind.
The audio panels are located behind the pilot/passenger and have integrated Bose ANR ports for the A20 headset or standard headset connections. The circuit breakers like mentioned above are on the passenger side for easy access to the pilot to pull in an emergency.
There are a lot of controls integrated into the stick grip which I think is pretty neat but also a safety feature. Elevator trim, flaps, pilot PTT, frequency swap, wings emergency level, and autopilot disconnect are the main functions I decided should be at my fingertips without trying to look at and fumble with buttons on the panel. Of course with more functions, comes more wiring and complexity but that of course now comes with experience.
I hope this gives a little insight as to my thought process and my OCD for a perfect panel. I’m sure I missed something, feel free to reach out if you have any questions!
-Tim
All lit up!
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