Panel Installation (Part 2)

Just to give some perspective on the whole instrument panel process:

For timeframe purposes:  

Initial Panel Design Started:  April 20, 2021 (See “Initial Panel Design” tab)

Panel Build Started:  January 12, 2022 (See “Panel Build” tab)

Completed Panel Delivered:  June 9, 2022 (See Panel Installation, Part #1)

These are two pictures I took on April 9, 2020, of the F-01467 Instrument Panel Frame (front and back) after it was Akzo primed and the 23 K1000-06 nutplates were riveted into place.

The two pictures below were taken April 10, 2020, after the Instrument Panel Frame was painted with SEM Medium Gray (same color as most of the interior).

And these two pictures were taken on January 23, 2021.  To complete the Instrument Panel Frame assembly and installation, an additional 12 K1000-06 nutplates were installed between the Frame, the Instrument Panel Attach Brackets and the Instrument Panel Standoffs.  That completed the Instrument Panel Frame installation and it’s now ready to accept the panel.  This picture was taken from the pilot side…..

…..and this one from the copilot/passenger side.


NOW, on June 26, 2022, the completed instrument panel was attached to the Instrument Panel Frame for the first time!!!!!  Aerotronics supplied the screws used to attach the panel to the Panel Frame (into all those nutplates).  They even went as far as painting the countersunk screw heads the same color as the panel (and provided a bag of extras).  To say I am happy with the panel is an understatement…..it came out perfect as far as I’m concerned.

Panel Installation (Part 1)

The finished panel from Aerotronics was delivered by ABF Freight on June 9, 2022.  I don’t have any “box opening” pictures, but the panel was packed into the box very, very well and resulted in no damage to the panel.  Now, lets get it into the plane!!!!!

Panel Build (Part 11)

Here is the COMPLETED panel!!  We love it!!

I will create a section in the blog for the panel installation.

*****This picture above is from Jason at Aerotronics on May 12, 2022*****

Panel Build (Part 10)

My panel is 99.9%!  The analog HOBBS meter on the right side of the panel is the last item Jason needs to mount (that I know of).  The G3X has a HOBBS meter function, but I decided I wanted an analog one mounted on the panel.  I would say you could call me old school, but that is the only thing on the panel that could be considered old school….so, that won’t work!  Additionally, the two open holes on either side of the dimmer switches will be for the seat heater (pilot and copilot) switches.  I will install those in the future when I install the seats and interior.  

I think the panel looks AMAZING!  With the unbelievable capabilities of ForeFlight, I will use my IPad to complete the panel.  ForeFlight and the GTN 750Xi will be able to communicate with each other for traffic, weather, flight plans, etc. This will be an awesome combination of capabilities.

Here is a picture behind what will be the sub panel…..

…..and behind the G3X PFD.

This picture shows the remote mounted transponder and comm radio and their associated plugs.  Jason just set them here for the picture (and to make everything work), as this is not where they will be mounted in the plane.  I have fabricated a bracket system to mount them behind the sub panel on the right side utilizing the “glove box” cutout in the sub panel.  I’ll do a section showing how I fabricated and mounted that bracket and avionics.

*****The pictures above are from Jason at Aerotronics on May 6, 2022*****

Panel Build (Part 9)

The panel for the RV-14, as designed by Van’s, calls for a modular panel (pilot side, center stack, copilot side).  I took this picture from inside N144VA, Van’s RV-14 demonstrator, when I got a ride following the factory tour in August 2019 (linked at the top right of the blog).  You can easily see the “separation” of each modular section.  There is absolutely nothing wrong with this setup and lots of people use this……not just in RV’s.

However, I wanted a “single panel” design without the “modular lines”.  I feel like it’s a cleaner and more finished look…..just my preference.  So, after a fair amount of back and forth with Aerotronics on what I wanted exactly, here is the end result and the finished panel the designed for me.  All of the panel labeling is etched and paint filled.  The tail number will be added later with some sort of white color matched sticker.  I’m going to see if my wife can come up with something better.  For the panel color:  Andre from Aerotronics contacted Classic Aero Design and got the paint codes that will match this color in our interior.  (The interior from Classic Aero Design will be captured in a separate section of the blog).

*****The picture above is from Jason at Aerotronics on April 27, 2022*****

Panel Build (Part 8)

The following picture was sent to me on March 9, 2022.  

Getting close to the end!!!!!  Almost there!!!!!  Jason just needs to wire the circuit breaker panel (mostly the bundle of red wires on the bottom left).  These wires will go into a plug that can be detached from the circuit breaker panel itself.  The last thing to do is cut off the zip ties and replace them with avionics string (which will be done when the painting and etching is completed on the final panel).

After the circuit breaker panel is wired….she has power!

Demo mode on the G3X PFD.

*****Pictures are from Jason at Aerotronics*****

Panel Build (Part 7)

Here are some updated build pictures from March 4, 2022.

Jason says the panel itself still needs molex connectors for the canopy and CO detector, but the wires are already run for those.  He has separated the wires that will run to the left common fuselage harness, the right common fuselage harness and the power wires that will run to the circuit breaker panel.

*****Pictures from Jason at Aerotronics*****

Panel Build (Part 6)

These two photos are from March 2, 2022.

More progress on the panel!  If this is how much wire that is going into my panel, just one panel…..can you imagine how much wire they have in stock at the shop???  Jason believes this is about the bulk of the wires that will go into my panel.  He’s guessing, but maybe less than 10 more wires to be complete everything.

The fascinating thing to me is that every wire has a purpose…..remove one of the wires and something does work properly!  Amazing!!!!

*****Pictures from Jason at Aerotronics*****

Panel Build (Part 5)

These two pictures are from February 23, 2022.  The first one shows the G5 and associated switches in/around it (backup battery power, magneto switches, test switch, push to start).

This pictures just shows the back of the panel and amount of wires that are starting to show up…..

*****Pictures from Jason at Aerotronics*****

Panel Build (Part 4)

The four pictures attached to this post are from February 22, 2022.  Lots of wires…..lots of them.  The panel is starting to come together.  Jason said almost everything on the panel is wired.  He will have that completed in the next couple of days and move on to the mating connectors for everything that will be off the panel.

*****Picures from Jason at Aerotronics*****

Panel Build (Part 3)

This picture is from February 2, 2022 and show the ADAHRS and Audio Panel fully wired, the PFD and GAD 27 partially wired and the various wire runs.

*****Pictures from Jason at Aerotronics*****

Panel Build (Part 2)

The two pictures are from January 20, 2022.  This shows most of the wiring for the GTN750Xi.

*****Pictures from Jason at Aerotronics*****

Panel Build (Part 1)

Now that the panel design has been finished/approved in Part #7, its build was assigned to Jason Springstead at Aerotronics.

First of all, I must lead this post by saying Jason was awesome to work with during the process.  To say that his customer service was good is an understatement!  He responded to all my questions (which he has probably heard the same questions a million times), on the phone and via email, within a day (usually within hours).  He was always honest with the answers to my questions and gave great advice on things that worked well together and things that did not (in terms of avionics).  During the build, if he had a question for me regarding the panel, he contacted me to see what I wanted…..instead of just guessing.  

I also asked him to occasionally send me some pictures of the panel build to post in this blog (finally getting around to doing that).  Jason sent me all of the panel pictures that you will see in the next several posts that will be published.

*****These pictures are from January 12, 2022*****

Jason said he tries to get as many items on the mounting tray as he can (second picture below)…..which leaves less items for me to have to mount somewhere off panel.  This is the front view of the panel with most of the items mounted in the panel templete:

G3X Touch 10.6” GDU 460 Display Unit

G5 EFIS

GMC 507 A/P Control Panel

GTN 750Xi GPS/Nav/Com/Map (I will have to install it when the panel is delivered)

This is the backside of the panel showing the “mounting tray” he uses for a majority of the equipment.  In this picture, you can see the:

GAD 27 Integrated Controller

GMA 245R Remote Audio Panel

GSU 25C ADAHRS

GAD 29 ARINC 429 Interface

Aithre Shield 3.0 CO Detector

Lastly, shown below are the items I will have mount off panel somewhere when I receive the finished product:

GEA 24 EIS Interface Module

GTR 20 Remote Comm

GTX 45 Remote Transponder ADS-B In & Out

TCW Intergrated Back-up Battery System 6 amp-hour

More to follow…..

Exhaust System (Part 4)

The following work was completed on Saturday, February 4, 2023.

Now that the exhaust has been installed, I started installing the Exhaust Gas Temperature (EGT) and Cylinder Heat Temperature (CHT) probes.  In the “Avionics and Panel” section of the blog, I talked about my decision to use Garmin Avionics and to have our panel built by Aerotronics.  When Aerotronics shipped me the panel, the EGT and CHT probes were supplied with the panel.  The probes they supplied were from the Thermocouple and Probe company Alcor.  This link specifically discusses the EGT probes and this link discusses the CHT probes.

I followed the instructions provided with the probes (same as directed to in the links) and installed the EGT and CHT probes.  In the two pictures below, I circled the four EGT probes and used arrows to point to three of the four CHT probes.

During the next work session on the Exhaust System, I will connect the EGT and CHT probe leads to their correct instruction leads from the Garmin GEA24 (Engine Indication System).  This step will also require wire runs to be figured out, connections covered with heat shrink and wire runs secured properly with adel clamps where necessary.  Still a fair amount of work to compete the probes install.

Exhaust System (Part 3)

The following work was completed on Friday, February 3, 2023.  

I started this work session by making the Forward Exhaust Hanger Brackets.  The first step was to modify two of the Exhaust Support Tubes.  Each tube had to be be cut to a length of 3 1/4 inches, have the corners of the bolt end rounded and the opposite end flared.  This picture only shows the rounded bolt ends of the two tubes.  Next, I used a band saw to cut the tubes to the appropriate length and flared the opposite end. (More on that below).

 One of the tubes is bolted to the Oil Sump and the other tube is bolted to an Exhaust Hanger Bracket.  The tubes are then joined together by using a length of rubber hose secured by two stainless steel hose clamps.  As mentioned earlier, the idea behind flaring the opposite end of the support tube is to create a lip preventing the rubber hose and hose clamp from sliding off the tubes.  

**Regarding the flared end of the tube:  the instructions say to use a vice to compress the end of the tube (to values shown in the plans), thus making the lip.  I’m sure the process works fine, but I didn’t really like it.  So, since all that is needed is a lip, I used a tube flaring tool to create a perfectly round lip all the way around the tube.  (Be careful not to make the flare to large or it will be difficult to insert it into the hose).  I liked the outcome this process produced on the tube.  The pictures below show a couple views of the completed and installed Forward Exhaust Hanger Assembly.

Next, I installed the Heat Muff Assemblies.  The assemblies are installed by first connecting the two stainless steel rods to the four Heat Muff Ends (two separate pieces make up each end).  The plans specify the length from the outside edges of the Ends should be approximately 7 3/8”.  The assembly is held in place by friction resulting from bending the inner “teeth” of Heat Muff Ends inward to create a tighter clamping force when the rods are installed.  This is the forward assembly….the rear assembly is installed in the same manner.

The Heat Muff Skin is now installed around the assembly and secured with stainless steel clamps around the Heat Muff Ends.  This is also the Forward Heat Muff.

This picture shows the forward and aft Heat Muffs completely installed.  There are six sections of Scat Hoses that now need to be installed.  I will wait until I finish running all the control cables, wires, etc before I install them to allow space to work.

Exhaust System (Part 2)

I was able to install most of the exhaust system from February 2 - 5, 2023.  This post is from the first session on Thursday, February 2nd.

Previously, I had explored other options for the exhaust system due to the backordered status of the Van’s supplied exhaust (at one point I was told 6-8 months).  Lucky for me, that time frame was greatly reduce and I received the Van’s supplied exhaust in a couple of months.  I had always wanted to use the Van’s supplied exhaust in the first place…..it was “designed” around the IO-390, Van’s used it on their prototype, it fit in the cowling, the install should be easier, etc.

I can say, the install of the exhaust system up to this point, has been very straight forward and has required NO modifications to anything.  It went together according to the plans and bolted to the engine perfectly…..couldn’t have been any easier!  (I know, famous last words)

Here is the exhaust (minus the heat shrouds) “connected” and ready to be lifted to the engine.  It did, however, take me SEVERAL minutes of spinning and flipping the plans around and holding up exhaust sections to make the picture in the plans make sense.  But, I eventually figured it out.

To begin the install, I had to remove the four blanks installed by Lycoming when they shipped me the engine.  (One for each cylinder).

When I ordered the engine from Lycoming, they sent it to me with preservative oil in it (which I requested) for long term storage…..the sticker on the side of box translated that to six months under “ideal conditions”.  When I took the blanks off the cylinders, about an ounce or so of the preservative oil also came out.

Here is where the blanks were installed for cylinders #1 & #3 (on the right side)…..

…..and cylinders #2 & #4 (on the left side).

Here is three angles showing the exhaust initially installed in place on the engine.