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Here we see the original panel in all its 1960′s grandeur.  The standard “T” layout hadn’t really caught on yet.  The attitude was over on the left, the altimeter was below the airspeed indicator.  And smack in the middle was the turn and bank.  So I just yanked it all out!  Wow what a mess. [singlepic=162,420,315,,left]

I had been contemplating modifying the panel for a while with out any clear direction.  The problem was where to cut and how much and how to accurately create the layout.  If you search my STC category, you’ll find the reference to Ron & John panel that I installed.  You can get more information by calling John Vanbladeren at 503-329-8512.

I’m glad that I purchased the STC.  After I ordered, I spoke with John three or four times getting the layout just right.  I didn’t even need any measurements!  They had measurements for every piece of avionics imaginable.  After finalizing the layout, I received a bare metal panel from FedEx.  All the large holes where cut but the screw holes were just tiny laser holes.  First step was to drill out these pin holes to fit #ten black instrument screws.  I lost track of the number of times I spent fitting all the gauges.  Here is a picture of one of those fittings.[singlepic=163,420,315,,center]

And of course all of those number ten screw holes had to be countersunk so the heads were all flush.  Next I moved inside and began cutting.  The old metal panel had to be completely cut out leaving a 1/4 inch lip all the way around the edge.  With a pneumatic angle cutter and an underpowered air compressor I went to work.  It was very slow work.  Grind away, sit and wait for the compressor to recharge.  I think I spent three or four days cutting out the panel.  Look closely at this picture just to the right of the avionics stack and you will see the cut lines.[singlepic=164,205,400,,right]  After all the cutting it was time to mount the panel by securing with screws all around the edge.  The panel arrived with five pre drilled mounting holes.  All the others had to be drilled by the installer, two to three inches apart.  Each screw was secured with a lock nut.  Some of the screws needed nut plates riveted on the back for clearance between instruments and the avionics.  So finally the panel was secured and it was time to dry fit once again.  I remember making a lot of cuts around the airspeed indicator to get enough clearance.  Once everything was fitting correctly and all the screws were secured,  it had to all be removed again!  Handling each instrument like an egg tested my patience. [singlepic=167,420,315,,center]

Time for some color.  I knew from the start that I was going to powder coat the panel.  I found a great place but they had way to many color options!  I looked at color swatches till my eyes were blurry.  I finally decided to go with a black wrinkle finish.  Its hard to beat black.  Never goes out of style and keeps the instrument reflection down.  [singlepic=166,420,315,,center]

From start to finish took right at a month.  If I added up the total project hours it would be at least two solid 40 hour work weeks.  Of course without the STC modification, that number would probably be tripled once you figured in the cutting and begging for approval from your local FSDO.

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