ben soaring wrote on 2/23/2021 4:14 PM:
Why bother chasing a new instrument panel? They are very expensive, hard to get, and a blank "factory" panel is difficult to cut properly and get "spot on".

This alternative method works great and actually offers "easier to service" benefits. The concept is to cut a new panel from redi-available and relatively inexpensive soft aluminum sheet then fasten the new aluminum panel to your old factory panel "skelton" by use of rivnuts. With the old panel completely stripped, "hollow" out the panel "face" creating a structural skelton to hold the new aluminum panel. It takes a bit of fiddle and fit but it comes together quickly. Leave as much lip as possible to maintain strength and hold rivnuts. Done correctly, it is hard to notice new panel is an overlay.

The best example of this was a 2 piece aluminum panel with a removable full length center section that allowed you to replace your flight computer in less than 30 minutes. The center section also mounted the transponder, switches, fuses, and USBs below the flight computer allowing complete access to the maze of all that without removing the canopy.

Beats the hell out of servicing something mounted to a factory panel.

How about just bolt on the new panel, then use a router to cut away the pieces of the old panel
that show through the new panel? That leaves as much of the old panel as possible. I like the
concept.

--
Eric Greenwell - Washington State, USA (change ".netto" to ".us" to email me)
- "A Guide to Self-Launching Sailplane Operation"
https://sites.google.com/site/motorg...ad-the-guide-1