Instrument Panel Construction
NOTE: this panel design is NOT recommended or indorsed in any way by Sonex.
This deviation from the plans is of my own choosing. I have taken care to insure
the strength and security of this change, as I have been informed that the panel
on the Sonex/Waiex is a structual member of the aircraft.
This deviation from the plans is of my own choosing. I have taken care to insure
the strength and security of this change, as I have been informed that the panel
on the Sonex/Waiex is a structual member of the aircraft.
Click on photos for larger view
To start with my panel is 1.5 inches lower
than the standard panel. This panel cost me
a weight gain of 2.8 pounds over the
standard Sonex panel.I also added 104
hours to the construction process by the
time all changes ans modifications were
complete.
than the standard panel. This panel cost me
a weight gain of 2.8 pounds over the
standard Sonex panel.I also added 104
hours to the construction process by the
time all changes ans modifications were
complete.
View Looking at the back side of the panel
on the co-pilots side. 1.5 x 1.5 x .125
angle was used as a staring point. .75 inch
was removed from the facing to provide
the required clearance of all items.
on the co-pilots side. 1.5 x 1.5 x .125
angle was used as a staring point. .75 inch
was removed from the facing to provide
the required clearance of all items.
View of attachment plate. Panel is on
opsite side. Pilot side was no the same
due to mixture control which was
designed to remain in place during panel
removal.
opsite side. Pilot side was no the same
due to mixture control which was
designed to remain in place during panel
removal.
This view demonstrates the prototype panel skin
in place during fitting. This took several trys
before the final panel faceplate was a correct fit
for all the switches, avionics, circut breakers
etc.. The initial panel skin was made from .020 to
allow easy cutting and fitting. The final panel was
.025 and was reinforced and braced a several
locations in order to support the avionics at
higher G-Forces. What seemed to be an easy
modification, turned out to be quite a challange to
do it right.
in place during fitting. This took several trys
before the final panel faceplate was a correct fit
for all the switches, avionics, circut breakers
etc.. The initial panel skin was made from .020 to
allow easy cutting and fitting. The final panel was
.025 and was reinforced and braced a several
locations in order to support the avionics at
higher G-Forces. What seemed to be an easy
modification, turned out to be quite a challange to
do it right.
The fitting process continues. After several dry runs it was time to finalize the panel (picture 1). All fitting was completed with the actual items
in place however, nothing was wired until the fitting was complete. The panel was designed to be plug and play. Ther were only 5 plugs total
and a grounding strap. This allowed the panel to be totaly removed simply by removing all the screws and unplugging the connections. You
will notice that on the mixture control the panel has a hole cut to allow the panel to fit right over the handle (picture 2). This has worked very
well in the years the aircraft has been in service as the panel has be removed on several services.I did all the wiring and installation of the panel
and even completed wiring diagrams with overlays. This makes trouble shooting very easy.
in place however, nothing was wired until the fitting was complete. The panel was designed to be plug and play. Ther were only 5 plugs total
and a grounding strap. This allowed the panel to be totaly removed simply by removing all the screws and unplugging the connections. You
will notice that on the mixture control the panel has a hole cut to allow the panel to fit right over the handle (picture 2). This has worked very
well in the years the aircraft has been in service as the panel has be removed on several services.I did all the wiring and installation of the panel
and even completed wiring diagrams with overlays. This makes trouble shooting very easy.
Picture 8
Picture 9
Picture 10
Picture
11
11
Picture 12
Picture 13
Picture 4
Picture 5
Picture 6
Picture 7
Picture 1
Picture 2
Picture 3
Once everything was fitted and the locations did not hinder removal and installation, i started on the trays for the transponder and com units.
This was necessary to support the heaver units during higher G-loads(see picture 9). The Garmin docking station was made by Air Gizmo. It
was real easy to install at this point in the construction process and allowed me to wire in all the garmin power and antenna connections into
the plug and play panel. It was time to start the wiring. you can see the com and transpdr trays with the units installed in (picture 12).
This was necessary to support the heaver units during higher G-loads(see picture 9). The Garmin docking station was made by Air Gizmo. It
was real easy to install at this point in the construction process and allowed me to wire in all the garmin power and antenna connections into
the plug and play panel. It was time to start the wiring. you can see the com and transpdr trays with the units installed in (picture 12).
UNDER REVISION