Panel

The Evolution of the Panel

	11/9/2004	This is the first shot at the panel. I'm only working on bulkheads but hopefully these things move along quickly. If Blue Mountain gets things in order and starts shipping the EFIS Lite, it's going to be the center piece of the panel. For a reasonable sum, you get an EFIS with both the AI and HSI capabilities. The CNS530 could also be replaced by the CNX480. I'm also thinking about the backup instruments. At this time I have the AI, AS, and ALT but the electric AI might be replaced by the Tru-Trak turn & bank that doubles as the auto-pilot controller. Switches, as shown above need to be relocated, probably to a sub-panel or under the radio stack. I like the JPI EDM-930c. I saw this at Oshkosh last year and it had the best display for any of the engine monitors. It accepts either capacitance or float fuel levels so that works for me. Oh well, decisions, decisions....Still have a ways to go but it takes a while to work these things out....
	1/29/2005	Here's another shot at this. I deleted the stand-by AI as the BMA EFIS G3 Lites are totally redundant. No dependency on each other so if one goes, I have the other. Additional CDI provides back-up for VOR/ILS/GPS. Also swapped out the CNS530 for a CNX80. I'll have to think about this one but it's a thought. Moved switches to just above throttle/mixture/prop for easy reach. Just playing with colors as well. Not quite sure about the cockpit colors yet, but I'm thinkin' about it. The TruTrak was upgraded to the DigiFlight II since I already have the servos.
	2/6/2005	Just working some revisions. Spread things out a little and added the additional color.
	5/14/2005	Stared at the above picture for a while and then started in with the TurboCAD Lite. Seems to work fairly well, at least for what I need. Couldn't find the right measurements for the BM G3s so it's subject to change. I've started working electrical planning and figured out there's a lot of switches. Most used go above throttle, flap to left of throttle, and several switches in the lower center for alternators. I've also extended the panel down an inch from the original drawing, so I might have to make my own panel. I thought this was a better solution than a sub-panel. If anyone wants, e-mail me and I can send the .dwg file.
	5/26/2005	As usual, these things have a way of changing. I've been watching a number of nasty little complaints about Blue Mountain Avionics. I really liked the looks of their Lite G3 display so I thought I was heading that direction (redundant units). A local RV-8 builder has just installed the GRT Horizon I and has it functioning in the panel. What a cool unit. Very nice. I've done some more digging and am really leaning in that direction. For giggles, I drew up a panel with the GRT unit instead of the BMA units. I think I can live with this. Until the next revision....
	6/03/2005	Based on the drawing in the row above, I modified my version of the epanelplanner.com. It's still the short panel and the drawings above have been lengthened by an inch. Still leaning towards the GRT Horizon I but we'll see how it goes.
	1/05/2006	Kind of back into the panel design as I move towards the cabin canopy install. I've been leaning towards the GRT units for a while and that really hasn't changed. Two GRT MFDs are used here as well as the EIS instead of the JPI unit. GRT seems to have a pretty good deal on this package. The GPS/NAV/COM is now the GNS 480 which shrinks the radio stack, and the switches for lighting are now on top of the radio stack. Hopefully, I seem to be getting close to a final design.
	1/20/2006	Really no change from the .dwg above, just added some fill to see how this was going to look.
	2/20/2006	This is pretty much final and I'm going to print. There were a couple changes I needed to make after printing a full sized plot from Kinko's and fitting to the fuselage. 1) The top row of switches needed to be moved to give some additional vertical room. 2) The switches along the bottom were moved up a little to give clearance for the switch body which I hadn't accounted for enough. 3) I may put a vertical row of annunciator lights on the left side but that's not for certain yet. 4) Van's panel files (that you can download) are the flat panel before the bend. So if you use their template, realize that it's going to be too tall by at least an inch. I found out too late so I had to make some changes, shown in the drawing at left. Otherwise, here's my panel after about a year of evolution.
	2/22/2006	No pictures, but I did send Stark Avionics a check for the PMA8000B, GTX327, GNS480, and SL-30 mount trays and wiring harness. Like eating an elephant, I'm spending the avionics dollars a little at a time. This is just a start I think.
	3/10/2006	Film at Eleven. I've been working with Ross at ExperimentalAir for the panel cutting. Looks like the drawing is about right so we're getting ready for the big cut. Over the last weekend I took the measurements for the avionics and sent them to Stark. That was on a Tuesday. I got a call on Friday saying that the harness is shipping. Now that's service! I received the trays last week so I'm pretty much waiting on the panel to start piecing things together.
	3/11/2006	The parts are starting to come in finally. Duffus picture, but the trays for the GTX327, SL-30, GNS-480, and PMA-8000B were received as well as a small order from Stein.
		Trying to determine how this all fits together, I made up a couple vertical rails for the trays. At lease the hole in the sub panel appears to be big enough, thanks to the mock-ups I had previously made.
	3/13/2006	Box of spaghetti. Very cool. Actually this is the Stark harness for the 480/SL-30/PMA-8000B/ GTX327. From an initial look at the wiring ball, it looks like it's a really good deal. This is going save a ton of time.
	3/14/2006	Also got the box from B&C with a bunch of switches, the LR3 external voltage regulator, current limiters, fusible links and the e-buss diode. Not done collecting the major parts, but at least getting close. I did get word from Ross that the panel was being cut this week.
	5/26/2006	The panel finally got here! After a lot of e-mail and a couple phone calls, I can finally move on! First on the agenda was to fabricate four of the tabs that hold the panel to the forward rails and the two vent brackets.
		Pretty simple, but took the better part of the morning to get these done.
		And here it is! Overall the panel looks really good. The CNC process leaves a fairly nice finish that just needs a quick file and scotchbrite de-burr. I have the 2.25 altimeter and airspeed and they seem to fit just right. I had to file a little on the cut-outs for the forward sills as well; it was just a little too tight. Now I know why Van's panels don't go to the fuselage sides under the sills, it's a real pain in the rear to get the panel in there. I'm wondering how this is going to work with a panel full of instruments.
	9/29/2006	Since I've been working on the canopy and getting the interior ready for paint, I haven't been doing too much work on the panel. However.... I did get a really big check in the mail to Stark Avionics for the all the fun toys. This is going to be really cool. I also picked up some interior parts from the local powder-coater (had gray parts turned to tan) in order to match the interior. Based on how that turned out, I may just have the panel done as well. We'll see....
	10/12/2006	Received a note from Stark that everything from his shop had shipped and should be here on the 18th. The GRT and TT items will be drop-shipped from vendors. Once I receive the radio stack, I'll continue fitting that, then move into the wiring harness work once the electrical components are mounted.
	10/17/2006	Got home from work and the TT DigiFlight II was sitting on the front step. Things are starting to show up.
	10/18/2006	During work today, Carolina signed for a really expensive box. The 480/ SL30/327/ and 8000B showed up! Whoo hoooo! This is going to be great! Also made an order from AS$S (Aircraft Spruce) that included a NAV signal splitter, a COM antenna, and the transponder antenna.
	10/21/2006	This is pretty cool. I already had the trays somewhat fitted so all I needed to do was slide the avionics into the trays. I did need to do a bunch of filing along the sides of the stack cut-out as it was just a little tight. Otherwise everything seems to fit OK. I'm having a problem with the 327 though. The aft lower surface of the front face is contacting the tray about 1/16" before the lockign cam can engage. I need to see if this can be adjusted. I've temp fitted the clock, TT DIgiFlight II control head, and backup A/S and ALT. I need to modify the lower left screw hole on the STBY ALT as the adjustment knob won't fit right. I need to order the TT 2.25" T&B Indicator and backup compass. Once GRT stuff arrives, most of the panel stuff is here.
	10/28/2006	Managed to drill and rivet the top panel stiffener angle to the panel today and it took a lot longer than I suspected it would. As I got towards the edges, the bend radius decreases and with the small notches, it makes kind of a facetted look to the top flange. I trimmed the flange that rivets to the panel to allow a smoother bend.
		I had concerns over the right panel rib getting in the way of the lighting switches but it's OK. I drilled a couple more holes for additional lighting controls and temp fitted instruments. The TT Turn and Bank should be here this week but the GRT stuff is going to ship 12/2. Bummer. I did have them send me a dummy AHRS so I can get that positioned on the electronics tray. I'm also trying to figure out the transponder tray. I have a different model tray than what's indicated in the installation manual so I've sent Stark a note to see if it's the one I should have.
		Picture is worth a thousand words... here's the drawing from the install manual. Note the lower edge of the tray as circled. This is part number115-00285-00. See the two tongs, they should slide into the aft lower face of the transponder.
		OK, see this? Note the difference. This pic shows the unit bottom side and the distinct differences in the area where the locking cam should engage. The whole lower edge protrudes, and there are no tongs to engage the unit. Per the stamp on the tray, I have 115-00431-00.
	11/4/2006	Got confirmation from Stark earlier this week that the tray I received is the right one. Got the trays drilled to new angle earlier this week as well, then drilled to the panel tonight.
		When I determined where the trays would go through the sub-panel, I was off by about 1/4", so I now have a little interference on the right side of the recess hole. Now I need to figure out how to get the trays screwed to the sub-panel.
		But I did get the panel rack mounts drilled to the panel. The overall radio rack seems to fit the panel fairly well.
	11/11/2006	I needed to figure out how to secure the radio rack to the sub panel. The available mount screw holes on the LS-20 and 480 trays were fairly far forward, enough where just a short piece of angle was not going to cut it. Luckily, I had my old panel which is convenient made of .063 and has a nice 90-deg bend already made. Time to scavenge the old panel for metal.
		I installed a bunch of plate nuts and temp secured this with #8 screws.
		Slid the tray in and marked holes for drilling. I'll secure both the SL-30 and the 480 to the sub-panel, then just use a couple of short tabs to secure the audio panel to the 480 and the SL-30 to the 327.
	11/17/2006	It's slowly coming together. Hopefully the TT Turn & Bank will get here soon and the GRT stuff is supposed to ship on 12/2. We'll see how that works. I did send the dummy AHRS back to them so I'm just awaiting the real stuff. All the switches except the lighting pots are temp install in prep for wiring and I located and drilled for 2 5A breakers for the Main and Stand-By Alt Fields (lower left next to vent). When I receive the Gretz pitot, the LEDs will go to the left of the compass and clock. I still need to drill for the Pax PTT on the right side of the panel as well as the ELT remote indicator. An indicator for main ALT failure is still in thought as I thought that the GRT will handle that. Need to double check before drilling a hole for an indicator.
	12/2/2006	And then depression set in.... I figured I'd pull the Stark harness out and see where all these ran. What a rat's nest! I am so glad I had them do the harness.
		After messing around with this for an hour or so, I'm finally figuring out how to route all these cables. The avionics back plates are only temp attached with a couple screws. I'm trying to figure out the easy way to screw these in but I'm not seeing any right now aside from just attaching the back plates before the trays are attached to the panel for good.
	12/12/2006	Finally received the TT 2.5" Turn and Bank from Stein. Only waiting on the GRT stuff. Supposedly, they were only waiting on the AHRS, which they should have had last week.
	12/19/2006	If you didn't know, Seattle got whacked by a pretty bad storm last Thursday and knocked power out to about a million subscribers. Not fun. So, it's been a long week so far with no power, thus no progress on the RV. I did hear back from GRT and my Horizon/EIS has shipped, although the ARINC is backordered until mid-January. Still, there's enough to do. This is really the last big item for the panel so I'm hoping to make some progress next week.
	12/26/2006	Santa came a day late this year but it was worth it. The GRT stuff finally arrived via DHL but the ARINC module was backordered. No problem, way too much to do until then!
		It didn't take much to temp fit the display units on the panel as this was what I was waiting for. Ca-chow (those with little boys would understand this)! I'm at the point where I can now press on with the huge majority of the wiring right now. There's a little structure work to do, like fitting the left panel support rib, but otherwise it's a winter of wiring coming up. If all goes well, wiring gets done this winter, then by spring, I'm ready to start the engine install.
	12/30/2006	I'm slowly making progress here. With the arrival of the dual GRT screens, I can finally figure out where to put the panel rib. So here it is and it wasn't a real big deal. I just ensured that the top screw hole for the panel was the same distance off the bottom edge, as the right rib. Other than that, fairly straight forward. One thing to notice is my "towel rack" below the panel ribs. There's nothing to tie switch wiring to under the panel so I used some spare j-stringer to run between the two panel ribs. Pre drill some 3/16" holes for adel clamps and you're there. This just gives me something to tie all the wiring down to. By the time this is complete, it's not going to move.
	1/7/2007	Been making progress on the electrical wiring but I did make some panel progress. After wiring up the both PLT and CP audio and mic jacks, the 8000B power and GND leads were connected. So far, so good. I seated the 8000B in the tray and locked it down then applied power. This was the first unit to get power so I was a little nervous here, but the lights came on as advertised. Checking the PLT jacks, I received good side tone through the intercom so that worked. I had Carolina get on the PLT side and I tried the CP side and what-do-you-know, the intercom worked. Cool. The only problem seems to be drop-outs from the PLT side every couple seconds when Carolina is talking. I need to determine if this is just a headset problem or an intercom issue.
	1/11/2007	What a messed up Winter! We got nailed with another 6" of snow this week. The problem is not the snow, it's the total lack of skills for driving in this junk by the indigenous population. A normal 20 minute drive home took 2 hours. Oh well. I did manage to get the dimmer hooked up to the audio panel and this worked great (kind of cool to see things start working), and got an e-mail back from PS-Engineering that the drop-outs are normal in a quiet environment. I've heard that they do produce one of the best intercoms, but I would think this might be an issue when trying to get clearance/ ATIS/ weather prior to engine start.
		On to Panel II