Electrical
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Panel Redesign – Part 5
Exported panel files in Solid Works to DXF format to upload into Front Panel Designer. Imported files and began placing text on panels. Used Futura font and 10pt size in most places. Printed out front panel designs full scale and taped to a cardboard mockup for test fitting once more panel components arrive. Hours Worked:…
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Panel Redesign – Part 4
Finished designing instrument panel assembly and creating drawings to print mockups prior to manufacturing Hours Worked: 1.86
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Panel Redesign – Part 3
Designed cutouts in stock panel blank to make panel cover removal easier. Began recreating assembly drawing with updated panel covers. Still need to model throttle and mixture controls along with circuit breakers Hours Worked: 2.89
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Panel Redesign – Part 2
Started to redesign panel layout. Used most of old drawing but transferred and confirmed dimensions into new files. Split panel into three separate files to make import into Front Panel Designer easier. Opted to remove bottom features due to clearance issues with ignition switch. Added bottom panel for throttle, mixture, and trim controls. Hours Worked:…
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Panel Redesign – Part 1
After discovering issues with the panel cover, reached out to Sonex tech support and obtained original STL file. Printed out layout and compared to existing panel blank; much better fit. Converted STL into Solidworks file for panel redesign. Hours Worked: 2.08
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Panel Decals
Updated CAD design to include tail number and passenger warning. Modeled trim wheel and updated dimensions for GPS175. Printed out design full scale and mocked up on actual instrument panel blank Hours Worked: 4.34
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Starting to Place Components
Created assembly file and began fitting components to panel cutout in SolidWorks. Created rough model for switch panels and GPS175 and inserted to panels. Laid out cutouts for panel power, light dimmer, and circuit breakers. Need to model cutout for ignition switch once dimensions are determined. Hours Worked: 3.00
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Creation of Panel CAD Model
Uploaded picture of panel into SolidWorks and created model of panel blank. Downloaded .STEP files of Dynon components and modeled cutouts per installation instructions. Hours Worked: 5.00
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LH Landing Light – Part 4
Protected LH landing light lens with painter’s tape and fit into opening. Trimmed lens per instructions, cleaned up all edges with rotary tool, and installed lower retaining strip with double-sided tape and packing tape. Felt strip installed around landing light opening. Hours Worked: 2.07
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LH Wing Wiring
Drilled passthrough hole in LH tip web and installed Heyco 2030 snap busing. Installed left wing wiring harness for tip and landing light. Created connectors LW01 and LW02 (DT style) and wired landing light. Landing light ops check good. Wrapped wiring harness near outboard vertical stiffener with shrink tube and placed tape on stiffener to…
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LH Landing Light – Part 3
Laid out landing light template on LH wing and trimmed opening for landing light lens. Cleaned up edges with rotary tool and scotchbrite pads. Created upper retaining bracket and riveted into place. Created lower retaining bracket and temporarily secured with #6 screws. Opted to not use flush screws on lower retaining bracket. Hours Worked: 2.58
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LH Landing Light – Part 2
Riveted together both sides of light mount plate. Installed #8 nutplates into mount and secured LH landing light and retaining ring to mount. Mounted complete light assembly onto forward ribs and checked operation of light Hours Worked: 0.55