Overhead console wiring complete

The main wiring task left was to terminate all the wires and cables going through the overhead console. We started by securing all the coax cable (8 total - 4 for the TAS, 3 GPS, and 1 for XM), then grounding all the ground planes together and connecting that to the firewall:

Antenna coax cables routed through Clickbond fasteners, with grounding wires connected to the ground plane

I then terminated the overhead light wires and O2 distributor wires:

O2 distributor and overhead light wires terminated in the console

While working on that, I realized the inserts I had already cut needed changes in order for the O2 DB9 connector to not hit the nutplates, so I spaced them further apart, moved the GoPro mount to the (lateral) center of the forward insert, and moved the AMPS hole pattern to the aft insert (this is meant for a RAM mount to secure a tablet or similar for passenger entertainment). I'll have that fabricated in the next few weeks so I can finish putting the overhead together.

Updated overhead console insert layout

With that, knowing the position/length the coax cables needed to run through, I could also terminate them on the panel side:

Using the side vent opening to terminate the coax cables with more maneuvering space

GTN/GNX GPS cables (left) and antenna ground plane connection (right) in place

For the GTN's GPS connection, the cable was close to the panel rib, but thankfully still far enough to be safe, once the panel was mounted in place:

GTN GPS (top) and COM (bottom) connections, avoiding the panel rib

The parts of wiring left are the switch pod, heat servos, flaps, the O2 regulator, and most of the FWF wiring.

Time lapse:


Total avionics rivets: 181
Total avionics time: 370.0h

Top TAS antenna installed

We trimmed and sanded all the excess fiberglass from the cabin cover around the TAS antenna, and then sanded/filled/sanded/filled/sanded it smooth:

Filling the cabin cover around the TAS antenna with resin (using peel ply)

Cabin cover area around TAS antenna, after sanding

After all the filling and sanding, we primed that area, and took the opportunity to also prime the COM ground plane extension and the cabin cover edge around it. 

Cabin cover area around TAS antenna, after primer (still with tape covering the ground plane)

COM ground plane extension covered with primer

Once that cured and all the tape was removed, the antenna was finally installed:

Cabin cover area around TAS antenna, showing the buried metal ground plane

Top TAS antenna installed in place

With the antenna in place, we started securing the cables inside the overhead console with Clickbond fasteners:

Clickbond fastener to hold all 8 antenna coax cables inside the overhead console

Clickbond fastener to hold incoming cables inside the overhead console

Next, I'll secure and terminate all the overhead cables.

Time lapse:


Total avionics rivets: 181
Total avionics time: 361.9h

Doors permanently installed

Once the cabin cover work was done, we installed the door seals - the original slot for the seal slanted "tabs" had been formed with the seals themselves, and it was basically impossible to get it in again, so we opened up those slots to let the tabs snap in, then installed the seals with some RTV to help hold them in place:

Carved-out slots for the door seals

Making the McMaster seal go into the slots

Once the RTV on the seals cured, we attached the doors and door struts:

First door permanently installed

First door permanently installed

Both doors permanently installed

Next up is installing the windows.

Time lapse:


Total cabin doors and transparencies rivets: 142
Total cabin doors and transparencies time: 204.6h