We finally started the final installation steps for the panel, starting with the antenna and AoA indicator atop the glareshield:
AoA indicator and GPS antenna on the glareshield
That antenna's cable cannot be easily trimmed, so I secured the excess cable to the top skin:
Excess GPS antenna cable, coiled up and secured behind the panel
I installed the G3X inserts and connected all the switches:
Left panel insert with all switch wires connected
I then cut the pitot and AoA tubes to length to connect to the GSU:
Pitot and AoA tubes connected to the PFD
The area behind it is pretty packed and hard to see, so by taking pictures and feeling the tubes with my hands, I could figure out what the tube was touching, and I slowly shortened it until it didn't touch anything anymore:
Pitot and AoA tubes running behind the PFD
I installed the IBBS battery permanently (but without connecting it just yet - too many connectors that take power from it are still loose):
TCW IBBS battery installed in place
I also connected the center console/armrest connectors, and in the process realized I trimmed the heat tee servo wire too short :/ so I made an extension for it to reach and connected it all::
Center console wiring, with the servo wire not reaching the controller
Center console wiring all connected, with an extension for the servo controller
Once the heat valve cables are secured to the firewall, I'll finish installing the rest of the panel.
In the meantime, I had a new version of the overhead console inserts laser-cut from 2024 aluminum, and we covered it (vacuum bagged) with carbon fiber, then did all the work of finishing it:
Overhead console inserts, after vacuum bagging with carbon fiber
Overhead console forward insert, still partially protected with plastic
Overhead console inserts after priming the top (hidden) side and edges
There's still a bit of finishing to do later, and I still haven't received the Clickbond dome nutplates to install on it (so we don't have any screw tips sticking up where the wiring is).
I also got back to firewall-forward wiring, starting with positioning the O2 sensor in place to know where its connector would sit (and thus being able to trim the cabin-side cable to length), then securing the top bundle to the coil pack mount:
O2 sensor and wiring held in place
FWF wiring secured to the coil pack mount
This also enabled me to trim the other end of the O2 sensor cable to size, and re-terminate it:
Spartan 3 AFR controller, with trimmed cable connected to it
Next we'll finish the overhead console inserts and install all the equipment there, actually install all the avionics in place, and continue the FWF wiring.
We attached the throttle and prop cables to the tunnel cover and the throttle quadrant levers:
Throttle and prop cables secured to the tunnel and levers
Cable ends secured to the quadrant levers
Turns out that there was still some interference with the center console in certain lever positions, so we sanded the center console lightly in that area:
Area of interference between center console and control cable
We then secured the cables to the firewall with the TTP-S fittings. I thought I'd have to secure them in an intermediate place (e.g. using F-1083), but they're still enough and held firmly enough in place by the fittings that there's no chance of them hitting the rudder pedal arms - we held them together with friction tape just to be extra sure:
Control cables running to firewall underneath the pedals
Control cables secured to firewall with TTP fittings
Control cables coming out of the firewall on the forward side
I secured the coil pack mount to the engine mount structure using a trimmed aluminum angle and Adel clamps:
Coil pack bracket secured to angle
Coil pack angle secured in place, before trimming
Coil pack bracket with angle in place
On that position, I also used the top hole to secure many of the engine wires with another Adel clamp:
Coil pack angle secured to the engine mount
Some people have asked me for a drawing to reproduce that part - here's the closest thing to that:
Coil pack angle with approximate dimensions
Coil pack angle secured in place (top view)
Coil pack angle secured in place (bottom view)
I also installed the oil pressure hose from the engine to the sensor:
Oil pressure hose from engine to sensor
This section also has you run the heat valve control cables to the panel (I'd expect that to be part of section 50, but oh well), so we attached those - one of the center side panel, the other to the center console insert, routed them through the firewall, and attached the center console in that position:
Heat valve cable secured opposite to electrical wires over the tunnel
Running the heat valve cable over the tunnel
Heat valve cables (on the copilot side and passenger console) installed in place
The main things left for this section are securing the heat control cables to the firewall and valves, and connecting the MAP sensors.
We fixed the rivet on the panel angle, which turned out to be due to the firewall angle hole being oversized - so we used a CR3243-4-4 oversize cherry rivet to attach it:
Panel angle attached with an oversize cherry rivet
We're using Skybolts instead of hinges for attaching the cowling to the firewall, so I started that by countersinking all the Skybolt flanges:
Skybolt cowl flanges countersunk for riveting
We also installed the glareshield cover, starting with cutting heatsink and cable holes through it:
Trimming the glareshield leather cover
Punching holes in the glareshield cover for attaching fan covers
Fan cover attached to glareshield cover
Glareshield cover installed in place
It was impossible to get the panel frame into place (get the holes to line up) with the thick leather+foam, so we removed the foam from most of the bottom part, which allowed them to fit together:
Removing some of the foam from the bottom side of the glareshield cover
I also opened a small slot on the flange of the panel in order to run the glareshield LED wires (the connectors will be hidden behind the panel frame):
Notch on panel frame to run LED strip wiring
We installed the panel frame in place, and tucked the glareshield cover in:
Panel frame installed permanently, with glareshield cover
I then secured the parking brake cable to the bottom side insert, and we installed it in place:
Bottom side insert with parking brake cable attached to it
Parking brake cable routing behind the panel, avoiding the center pedal bracket
Parking brake cable routing behind the panel
If I knew the whole geometry of this cable run back when I installed the Beringer system and hoses, I'd definitely have placed the parking brake valve in a different location (maybe above the center tunnel, or even on the firewall).
I also had to trim the top edge of the side panel to give avoid the bottom connector from the VP-X (seen above).
Last but not least, we attached the arm rest cover to the center console:
Center console with arm rest cover installed
Inside the center console pocket, underneath the arm rest cover
The main thing left in this section is the cowling attachment, since between this and other sections most of the panel's structure is in place.
Time lapse:
Total upper forward fuselage installation rivets: 153
Total upper forward fuselage installation time: 42.7h
Once the engine mount was in place, we could finally attach the floor covers:
Forward floor cover panel installed
I also opened a slot on the tunnel cover for wires - I was originally planning to run the wires through it with the cover in place, but after actually doing the tunnel wiring I realized what a royal pain that'd be:
Tunnel cover slot for wiring
Tunnel covers installed in place
Tunnel wires running through the cover
I attached the seat floors for good:
Seat floor installed in place
We also started trimming the forward interior panels, but that'll take some more work to finish.
