However, while doing that, the head of one of the little #4 screws broke. Lesson learned, I'm not using brass screws for that anymore (I had picked them just because they were black - bad idea), but we still had to remove it, which took a couple hours, and in the process of doing that we ended up bending the nutplate, so in the end we just replaced the nutplate:
Bent nutplate in the overhead console
We're still working on finishing their surface, and a future post will show them installed:
Overhead inserts with resin applied (sanding and more filling still needed)
Meanwhile, I installed the bottom center panel insert, which let me to realize that the alt static connection wouldn't work as I originally intended, so we moved the T fitting to the right side:
Bottom center panel insert installed in place
Static T fitting connecting the tube coming from the static ports, the alt static switch, and the avionics
Tube routing down to the alt static switch
Final assembly of the top center panel insert was an exercise in patience, and ensuring nothing physically interfered with one another (and fixing the few cases where something did):
Clearance between the G5's static line and the circuit breakers
Vertical clearance between the main static line and the light switches
Interference between the GMC507 connector and the main wire bundle, which had to be fixed
Center panel insert and wiring secured in place
I then installed the actual displays, which posed some new interference challenges to be addressed:
Static tube running too close to the GAD29
Static tube run after trimming
PFD/AHRS connectors
AHRS tube connections
Panel mostly operational
With all that in place, it was time to test it all again and fix any remaining squawks - one of which unfortunately was that the LED strip connector had come loose, which requires removing the PFD and the left-side insert to fix. I also adjusted the position of the door sensors so they reliably open and close.
There's not a lot left on the avionics front - installing the overhead inserts, the ELT, the rudder trim servo, and once the wings are attached, connecting them.
We attached the reservoir to the firewall, then attached the last hoses to it:
Brake fluid reservoir attached to firewall
Brake lines connected to firewall reservoir
We later connected the parking brake cable to its valve - we initially tried to use the McFarlane tip for the conduit, and then adapting that tip's M6 thread to the ~10mm hole of the Aircraft Specialty valve bracket:
Thread adapter attached to parking brake valve bracket
Eventually, we realized we could just use a Bowden cable clamp from Spruce, which has fewer parts and would hold the cable more securely, so we switched to that:
Parking brake cable installed with Bowden clamp
With this, only the final assembly steps - filling the brake lines, and attaching the rudder cables - is left for this section.
I tried to install tubes and clamps connecting the forward air vents to the panel vents. When I did this, it became apparent that there's some contact between the vent extension tube (where the tube is secured) and the subpanel structure, since I couldn't get the tube in. . When we installed the panel it required a little bit of force to get it to align with all the screw holes vertically, and we couldn't figure out why - now it makes sense, when I originally assembled the panel I did not have the back part of the vent in place.
Interference between the panel substrate and the air vent
We trimmed that tip with the Dremel (awkward positions involved), primed the tip again, and finally installed the vent and connected it to the air intake (and at this point, we secured the tube to the vent extension before screwing the vent in place, which made it a lot easier):
Trimming the panel substrate to clear the vent extension
Trimmed panel substrate
SCEET tube secured between the left vent extension and the air intake
SCEET tube secured between the right vent extension and the air intake
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:
Vacuum-bagging carbon fiber to finish the metal overhead inserts
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.
