https://www.pilotdan.com/glasair-iii daily 0.75 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506475682580-0U6AOKLE0DGY074MHVCZ/IMG_0661.jpg Glasair III https://www.pilotdan.com/glasair-iii/2018/2/7/wing-jig-part-ii monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518053938210-WHY8NOFRF86U56LWJKK5/IMG_1134.jpg Glasair III - Wing Jig Part II These are the five cross pieces. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518055625981-BXGM1Z3LJEUZQ963DQ4Q/IMG_1176.jpg Glasair III - Wing Jig Part II With the frame level, I attached the templates to the top using 2x4 guides. The templates can still float fore/aft and can be shimmed up/down. This view shows the relief for the landing gear. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518053861236-EN2VMZ01CYS5ICDJFUQ8/IMG_1132.jpg Glasair III - Wing Jig Part II Here's my Dad cutting the LVL's for the cross pieces to size. One of the ends is tapered 4.5deg. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518053795375-3ECAE2TJCR5U2S0YRYRU/IMG_1128.jpg Glasair III - Wing Jig Part II These are the two 23ft long LVL's that make up the sides of the torsion box. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518055450081-U0XIPSS2QRDA53BAV3TP/IMG_1168.jpg Glasair III - Wing Jig Part II Next we added 5/8" plywood to the top and bottom to give the jig torsional stiffness. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518054951024-GIAQG50F4XDBZHTLD6XP/IMG_1140.jpg Glasair III - Wing Jig Part II We drilled all of the holes with the drill press to ensure the holes would be perpendicular. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518055367973-GNT9WMQKCZ60QQ3V67PH/IMG_1164.jpg Glasair III - Wing Jig Part II Here is the completed frame. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518055123494-XSVAPVPITUIFJ6C2YF5N/IMG_1144.jpg Glasair III - Wing Jig Part II I MIG welded the bracket and sprayed it with a coat of paint to prevent any rust. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518054667989-EPHEQMAP1YAY1XY4X3C4/IMG_1136.jpg Glasair III - Wing Jig Part II All of the LVL's have been cut. The back piece is angled to allow the landing gear to clear while the wing is still on the jig. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518054760189-7LT2BQLD9AFQ7B4GJ6Y9/IMG_1137.jpg Glasair III - Wing Jig Part II To attach all three pieces together at the back center, we fabricated a steel T-bracket. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518054999475-4XGDEVEN04DO5LKFDSWC/IMG_1141.jpg Glasair III - Wing Jig Part II After screwing the pieces together with 1/2"x5"long lag screws we double checked for square. Looking good so far! In the background you can see the laser we used to level. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518055198338-3KYW9X608QWNFBB8WMHO/IMG_1161.jpg Glasair III - Wing Jig Part II Attaching the back pieces. The green corner clamps were very handy during the whole construction process. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518055272852-JKRNN2MOQTO8CUF70N6R/IMG_1162.jpg Glasair III - Wing Jig Part II This plate ties the two back pieces together. The four extra holes are for the leg. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518055527625-Y49GE2NH5ZVTJYT1SJZ5/IMG_1169.jpg Glasair III - Wing Jig Part II The 2x6 legs are attached with four screws. They have threaded inserts in the bottom and adjustable steel feet. They are extremely sturdy. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518055727052-YBEL77V85DVAL21EWY9U/IMG_1184.jpg Glasair III - Wing Jig Part II Here is the finished jig with the wing installed. I only have the "B" and "E" templates installed for initial shimming. I will go back later and shim the "A", "C", and "D" templates. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518054830133-4ETBFUKDYWF6NSIMQD4J/wing_jig.jpg Glasair III - Wing Jig Part II I modeled it in CAD to get measurements and angles. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518055325128-28CG5J745PKEKTGORX5Q/IMG_1163.jpg Glasair III - Wing Jig Part II Overall, the bracket turned out to make a nice stiff joint. https://www.pilotdan.com/glasair-iii/2018/2/7/titanium monthly 0.5 2018-02-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518057457074-12Q91LUU7SKBR12ARL89/IMG_1087.jpg Glasair III - Titanium! The back side came out great! No contamination. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518057339796-ZO1EK99J44Y1C27YZ9AH/IMG_E1085.jpg Glasair III - Titanium! Here's the bung, welded in place. Very slight oxidation (straw colored) is acceptable in the weld, anything more (brown, blues, purple) is cause for rejection. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518057268453-9NKLUI7Y50LH9QYKD9F9/IMG_1086.jpg Glasair III - Titanium! When welding titanium, every part of the joint must be shielded with argon. I made this tent to cover the back side of the welded and tape it on with aluminum foil tape. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518058087664-Z6G6ZU7I2W9UWW6WU9KZ/IMG_1195.jpg Glasair III - Titanium! Here are the finished pieces. The steel ones are on top. I could probably save a little more weight on the Ti ones by rounding the corners! https://www.pilotdan.com/glasair-iii/2018/2/7/bellcranks monthly 0.5 2018-02-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518058745698-U8RBNN7OUJ8MKR66I4LY/IMG_1069.jpg Glasair III - Bellcranks The rudder stop is made out of 1/8" 2024-T3 aluminum to keep the rudder form over traveling. It is made oversized then trimmed once installed on the aircraft. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518058962580-121G3WUSRS18BGQOPG24/IMG_1073.jpg Glasair III - Bellcranks Light weight and easy to make! https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518058905444-19Y3WDNQZGM4WULAVY98/IMG_1071.jpg Glasair III - Bellcranks The aileron bellcranks are assembled from two halves and a flanged bearing. Six solid rivets are used to sandwich the whole assembly together. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518058775739-F0G9HOGKZIK4VX6KZV6J/IMG_1070.jpg Glasair III - Bellcranks Looks like the picture! https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518059098328-B4ZU5HAYCBFIC92376HL/IMG_1076.jpg Glasair III - Bellcranks While I was making metal bits, I decided to make these landing gear door brackets. These will also get tumbled and anodized. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518058990250-S7TT2WHJMVQZ3O7UPJNX/IMG_1077.jpg Glasair III - Bellcranks The elevator bellcrank is similar construction. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1518058655691-ZFR93U2EBD9BSUYAQPQL/IMG_1068.jpg Glasair III - Bellcranks Rudder bellcrank brackets. These are fabricated from aluminum angle and attach the rudder bellcrank to the tail. I'm going to tumble and anodize them to get the finish nicer. https://www.pilotdan.com/glasair-iii/2017/11/5/wing-jig monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509926432283-VMBFHTKO7YRMTSC3OVO8/IMG_0917.JPG Glasair III - Wing Jig Cutting the template to size on the table saw https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509926459305-B68H3OS7IDZA2794DSDG/FullSizeRender.jpg Glasair III - Wing Jig https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509926355693-AUKE6Q5UBCWA6GL86I1K/IMG_0915.JPG Glasair III - Wing Jig Paper templates are transferred to plywood https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509926445405-CU76DS84GH8MWGYWRAVG/FullSizeRender.jpg Glasair III - Wing Jig https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509926472149-65JBPBUXBWV7LBTLEPEC/IMG_0921.JPG Glasair III - Wing Jig https://www.pilotdan.com/glasair-iii/2017/10/25/aileron-bellcank-brackets monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1508933291298-25PP22ZN12IRBNBS5TOI/IMG_0819.JPG Glasair III - Aileron Bellcrank Brackets Backing plate made to size of paper template. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1508935258098-GJNZLEYTYZING3YYF86C/IMG_0855.JPG Glasair III - Aileron Bellcrank Brackets https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509318335105-WA5EAG2BIL1PK2P4GAOP/image.jpg Glasair III - Aileron Bellcrank Brackets https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1508932887939-I4UUXWDW102CZAWT0Q9X/FullSizeRender.jpg Glasair III - Aileron Bellcrank Brackets https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1508933023859-T43EW35NU6IW1POI9SPA/IMG_0814.JPG Glasair III - Aileron Bellcrank Brackets https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1508933112409-QK5MD87AFYF00HQPJSN2/FullSizeRender.jpg Glasair III - Aileron Bellcrank Brackets https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1508935237202-S9CDZVPM661IAW692OPW/IMG_0821.JPG Glasair III - Aileron Bellcrank Brackets https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1508932809223-TQX1R8IDVY3CS0GAY118/FullSizeRender.jpg Glasair III - Aileron Bellcrank Brackets https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1508932951149-N9KF3C0O1BHCNV22QNAF/FullSizeRender.jpg Glasair III - Aileron Bellcrank Brackets https://www.pilotdan.com/glasair-iii/2017/9/27/the-glasair-iii-kit monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506564133718-X38MT0VGV85WALXXLC7I/image-asset.jpeg Glasair III - The Glasair III Kit https://www.pilotdan.com/glasair-iii/2017/9/27/getting-it-home monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565666541-KIRFBBAHQGGKJCD51XPR/IMG_5653.JPG Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565675698-3WX7H48D29YTXXO5YWGC/IMG_6066.jpg Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565673702-9IHMYX8EZG6E56ZPWT3U/IMG_5898.jpg Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565673716-RZT6OCF94UD4MUTUYT8H/IMG_5922.jpg Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565674836-A5YSHARO47JEWLP221MS/IMG_5923.jpg Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565675294-3P8KTC2D5JZ4JMWCHR38/IMG_5992.jpg Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565675247-RQDSYZT0M4MJWCHCW1XW/IMG_5981.jpg Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565674855-10SL1L3IXKKSB0KGEBPV/IMG_5976.jpg Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565675614-RZVKNBWWDHVQ6P0K96EK/IMG_6009.jpg Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565672682-6SYCAL7F72CTYALEQOC6/IMG_5670.JPG Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565671886-0X2WSTDF922D3C3XB3FZ/IMG_5669.JPG Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506565841996-DFCD45Q10DLA7T029XNO/IMG_6091.JPG Glasair III - Starting a GIII https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506566902862-B3AEJXCLH0MQ7JVZIQHV/IMG_5728.JPG Glasair III - Starting a GIII https://www.pilotdan.com/glasair-iii/2017/9/27/it-all-started-with-a-ride monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506568435402-9ZODQ6HWP0F9E2F6G6K5/IMG_0316.jpg Glasair III - My first ride https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506568462192-MI7334A4XXZXADOMJNK4/IMG_0315.jpg Glasair III - My first ride https://www.pilotdan.com/home daily 0.75 2017-09-26 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506556540875-GU3KJRSXSIME8AWXBQSX/IMG_6699+2.jpg Home https://www.pilotdan.com/n729s-1 daily 0.75 2018-11-20 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506474816557-R9MT3PKR1TUQJEP0DR0Q/IMG_6714.jpg N729S https://www.pilotdan.com/n729s-1/2018/11/19/oshkosh-2018 monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542684098779-9VR6QFKFH153OSYY38B4/IMG_1758.jpg N729S - Oshkosh 2018 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542684130689-ZUZJKOAITGTIE0B5FSCU/IMG_1766.jpg N729S - Oshkosh 2018 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542684162163-DDCUCSGCA76PHW20FYB6/IMG_1888.jpg N729S - Oshkosh 2018 https://www.pilotdan.com/n729s-1/2018/11/19/spring-maintenance monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542683762664-4U42RWGZ01P9VPOFKUHY/IMG_1264.jpg N729S - Spring Maintenance https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542683805478-8O2QSIDUF6CH25JR3YJG/IMG_1395.jpg N729S - Spring Maintenance https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542683839165-SYX2KKVEW2RS1MOMF1OO/IMG_1408.jpg N729S - Spring Maintenance https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542683784605-YA3ICIMOVGEN6MCRH8HE/IMG_1285.jpg N729S - Spring Maintenance https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542683734361-0ZM47PSV3W1H5H5KFD9I/IMG_1256.JPG N729S - Spring Maintenance https://www.pilotdan.com/n729s-1/2017/10/31/exhaust-repair monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509505551652-E5UM0ECW6DAVLLTSLAU6/IMG_0906.JPG N729S - Exhaust Repair https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509505353142-66M7EH3PGW1FF9C4MRC1/IMG_0893.JPG N729S - Exhaust Repair https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509505818696-5BBN0DLFXNX20IMH9O1R/IMG_0902.JPG N729S - Exhaust Repair https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509505477460-MCCE903ULJW2SIRM3911/IMG_0907.JPG N729S - Exhaust Repair A finished flange https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509505655579-7G3XAFXZFZLFIP9P5YR1/IMG_0895.JPG N729S - Exhaust Repair https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509505243236-O9WH9FBAGSDUIXV0PXNO/FullSizeRender.jpg N729S - Exhaust Repair Spark plugs as they came out of the engine. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509505964950-0ZDMQJS2DMVDQFLF9SQ0/IMG_0898.JPG N729S - Exhaust Repair https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1509506063732-A4RU6HA77NO14O9VBTOS/FullSizeRender.jpg N729S - Exhaust Repair https://www.pilotdan.com/n729s-1/2017/10/5/and-then-i-found-five-dollars monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507249377884-B2IR7C1JG79EV1D0ODT9/IMG_0750.JPG N729S - ...and then I found five dollars https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507249339553-NATLJ5PZX543J9YI70K4/IMG_0752.JPG N729S - ...and then I found five dollars https://www.pilotdan.com/n729s-1/2017/10/3/building-time monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507082042858-3H8Q7C9IT9D83T4Z607Q/FullSizeRender.jpg N729S - Building Time Spruce Pine - Avery County https://www.pilotdan.com/n729s-1/2017/9/28/the-aerial-commute monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506640751211-3CQLIUV09KM6C615JZB8/IMG_0715.JPG N729S - The aerial commute https://www.pilotdan.com/n729s-1/2017/9/26/lets-get-started monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506475312731-IFWJ210JPGHT0TTR42HZ/IMG_5324.jpg N729S - Let's Get Started https://www.pilotdan.com/n729s-1/2017/9/27/finished-panel monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558498018-DXGDIL2WU5S2X7C8C74N/DSC_1338.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558494967-R9V6IERGBD7927PC5QH3/DSC_1342.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558501333-PZBNMOE82AW5P728FNWP/DSC_1344.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558504573-T7VB39XXUEKZSLI5R9M6/DSC_1346.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558509090-X33VK6BRON4K04AIC6OG/DSC_1347.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558513723-NNMUNUDBW8WGPHWN48DN/DSC_1348.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558517287-7VJ35ZNXCHFDJY7U0RST/DSC_1350.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558519946-ASYWE72709ZAFLOVCCCF/DSC_1351.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558527752-DRNFO6ALU9ZIFPNSGWRP/DSC_1357.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558529824-ZN5G4IC4T7SUJQ20JWCL/DSC_1358.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558534337-1I5ROI89WUISUKRKDFDV/DSC_1359.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558537166-YUXUGPA99T6AJLJ33E5Q/DSC_1360.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558540937-Y97E7JOMBN8C7VCXD3ZO/DSC_1363.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558544439-8PD20N5H1GW4A92UIKO2/DSC_1366.jpg N729S - Finished Panel https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1506558546950-4JQQFMC6OYAWOMIQFGRV/DSC_1369.jpg N729S - Finished Panel https://www.pilotdan.com/n729s-1/2017/10/5/panel-overhaul-part-ii monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507248393384-HDCBNGUL170C9SGJ7NK8/IMG_5756.jpg N729S - Panel Overhaul - Part II It's starting to look like a cockpit again! https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507246648808-WBB1LNXKWRQ2MR9BERL0/IMG_5692.jpg N729S - Panel Overhaul - Part II Tools of the trade... https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507246400353-68EYN92UC3J429S29AJD/IMG_5683.jpg N729S - Panel Overhaul - Part II Here is a view of the back of the GNS530. The red silicone tape provides a nice cushion for the strain relief clamp. The green wires are the shields that terminate to the chassis of avionics. The blue solder sleeves are splices for power/ground/ or signal. When running each and every wire, I like to imagine it constrained with just enough support to keep it from vibrating, but not enough to create tension on the connection. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507247001495-9V84PHG3KKHTN2OASMLM/IMG_5691.jpg N729S - Panel Overhaul - Part II https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507247004101-CNT215E1RXVFM5SHPJFW/IMG_5707.jpg N729S - Panel Overhaul - Part II https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507247006571-VU5WPXAF6S6K7XKCFXO1/IMG_5705.jpg N729S - Panel Overhaul - Part II https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507247008522-NJVO0DH4TM8Y7KVMJA7H/IMG_5706.jpg N729S - Panel Overhaul - Part II https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507245725120-H6QPFIF0PJLAFCR97KEF/IMG_5322.jpg N729S - Panel Overhaul - Part II I started with the engine sensors. You can see the black nylon lacing around the wiring, and the black silicone tape around the engine mount wherever there are tie wraps. Every connection has a strain relief loop, but is well supported to combat fatigue from vibration. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507247191238-ZTWAL5VN65SK6BDVAPLV/IMG_5740.jpg N729S - Panel Overhaul - Part II As the connectors start to be assembled, the wiring cleans up nicely. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507246908580-BZQCU1CP7SIMFPWA5DKH/IMG_5690.jpg N729S - Panel Overhaul - Part II All of the toggle with and circuit breaker wiring is run long and labeled with masking tape and a Sharpie. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507247265722-S8KLEVK62CC5NY5PFSNY/IMG_5737.jpg N729S - Panel Overhaul - Part II The switches in the center console are given generous strain relief loops. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507248330429-288T0WHWUJ10BMCCHI9G/IMG_5758.jpg N729S - Panel Overhaul - Part II All of the ground wires terminate at the brass "forest of tabs". I left a few extra taps just in case I add anything in the future. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507246256708-NRKHOIQYVVPLFCZNX0BB/IMG_5684.jpg N729S - Panel Overhaul - Part II https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507246259954-TCSI1RX5JK6T6TGMRRI4/IMG_5685.jpg N729S - Panel Overhaul - Part II https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507247594419-XLP8GYQT3B7BXYT4EO84/IMG_5761.jpg N729S - Panel Overhaul - Part II Wiring to the bus bars and circuit breakers. Power goes in through the large 4AWG wire, through the copper bus bars and circuit breakers, and out the small wires. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507245855566-IS7TLY0Z5MM9VZCQ3ZZZ/IMG_5306.jpg N729S - Panel Overhaul - Part II This is the forest of tabs that provides the grounds for all of the components. The tabs have been riveted to the brass strip, but still need solder for a solid electrical connection. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507247308209-U50RXEFXYL3A3JOI1CU9/IMG_5746.jpg N729S - Panel Overhaul - Part II The remote COM is all tidied up with proper strain relief and support. The rogue wire is the bonding strap to ensure the chassis is grounded. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507245936669-8UYC8LWDXLIB1ECZO1LI/IMG_5533.jpg N729S - Panel Overhaul - Part II https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507246017747-QY284LGGDIXUCJX708GU/IMG_5532.jpg N729S - Panel Overhaul - Part II https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507246024401-5XXB5BF0Y5UPPMBL43LX/IMG_5553.jpg N729S - Panel Overhaul - Part II https://www.pilotdan.com/n729s-1/2017/10/5/panel-overhaul-part-i monthly 0.5 2018-12-08 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1512433263890-7O3ZK2L4E1I7K924CA3A/Panel_CAD2.jpg N729S - Panel Overhaul - Part I Panel layout completed in CAD. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244727589-TVSEM77LEXZJJ88BQZH7/IMG_5243.jpg N729S - Panel Overhaul - Part I https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244734346-TJ2A97128DUIF2LLTQ0W/IMG_5257.jpg N729S - Panel Overhaul - Part I https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244738532-R5IX8CD1MG3Z31D14ARS/IMG_5258.jpg N729S - Panel Overhaul - Part I https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244743173-KQ7L3MN08N4SNZZTY4O5/IMG_5261.jpg N729S - Panel Overhaul - Part I https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244749140-YCXYY0TTDK7UVMQGL7CY/IMG_5268.jpg N729S - Panel Overhaul - Part I https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244920032-6NXBGPX7XL29INQKAGRD/IMG_5302.jpg N729S - Panel Overhaul - Part I The dual GPS antennae got new BNC connectors and a custom fiberglass tray. They will sit at the very top of the fuselage behind the baggage compartment. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244091482-HEDE2FXRENEDPZ0ME8LG/IMG_2797.jpg N729S - Panel Overhaul - Part I Beauty is only skin deep, here is some of the shoddy wiring. This is more common than not in legacy GA aircraft. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507243985166-734RY45LSP5E2TR6FCNA/IMG_2807.jpg N729S - Panel Overhaul - Part I Very Capable IFR panel. https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244547573-BULX4P9USINCRFZC1UTJ/IMG_5183.jpg N729S - Panel Overhaul - Part I https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244563413-GW0BRHQJSGW25MDNGC57/IMG_5187.jpg N729S - Panel Overhaul - Part I https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244571342-8YCJ86OTTUXH3I7CFSBV/IMG_5186.jpg N729S - Panel Overhaul - Part I https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244590818-BIE50OSQZW8PEYWDIE9V/IMG_5246.jpg N729S - Panel Overhaul - Part I https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1507244864826-IX2DBP0XWIAHCS1MUYF3/IMG_5286.jpg N729S - Panel Overhaul - Part I The Nav/Strobe lights got new DTM-4 connectors. https://www.pilotdan.com/workshop daily 0.75 2018-12-08 https://www.pilotdan.com/workshop/2018/11/19/downdraft-table monthly 0.5 2019-04-10 https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542684724475-22P6D7ND4CEFVRITZNGX/IMG_2292.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542684901993-XL1496E7JS121WN94CL6/IMG_2302.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685031860-K0O82MKUS4NZSXHJZNZE/IMG_2435.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685694985-9XQDQQ6SH3WHKXCLRQHP/IMG_2560.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542686057222-B03FN25PNMETV4FZXAHS/IMG_2632.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542686057183-P8RSQGBQTTO4UZ7AR9F0/IMG_2634.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542686061211-EXNX4A7CB1IY4F7ODSVT/IMG_2636.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542686061533-JPW4EZU25Z0PI7KU5IKQ/IMG_2638.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542681863309-AU7ZV25C7EC8RXLFTJ8Y/IMG_2282.JPG Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685123260-2M8QMTOL0KUSDH46BLWO/IMG_2440.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685195878-WKO0FUS9FPUCSJVLDITN/IMG_2473.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685338504-UG8LVR0N2LYHK5OU698V/IMG_2482.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542684927069-U8Y3KU9WPW0Z7NR1ZE60/IMG_2415.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542684823494-H9OAI0YVJ7FN6F7IJ6FI/IMG_2299.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542684823892-98QOZ5BDMRTOHDQDHTY3/IMG_2300.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685370833-3GVYIVIQZZB5M0LS845C/IMG_2553.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685873502-9PCX10NJ3FI2EU0KYBGD/IMG_2587.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685852810-A4QIN6L9ZDXXKZBJL31Y/IMG_2588.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544313093255-206LL78OLLY1IMWYA44S/IMG_2287.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544313626626-6B5WFV0V6DB506UE5GAH/IMG_E2293.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685084297-EEFBRU536P5JHJ8M9JYO/IMG_2437.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544316806224-M4M2KAYSJAUQVLBZ7UBD/IMG_2650.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544316801441-H90WAEYVFSSCLMROCR0J/IMG_2642.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544316799963-SXME69066I3VNJF51ZMV/IMG_2644.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544316805261-WI173N4PB1YZVG6J8YRQ/IMG_2645.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544316819319-W8Q10IXAAAN8EKC08YHZ/IMG_2652.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544316815302-ZK8T43DXAKYWQ4GYX72H/IMG_2654.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544316821744-A62C6BXPGHC58Y2DBG3P/IMG_2657.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544316824492-Q0P1DO7BI641ZVY26OCO/IMG_2658.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544316828480-QIEUH9NQCQPPFRQHF5NQ/IMG_2659.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544316829207-Q4EWQ154466VOYLYNS6E/IMG_2660.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544316832012-XVW7S2PN0FF0C39CPAVT/IMG_2661.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685310470-CEROTEPETAES0NB4B4SK/IMG_2483.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542684678375-2NW9395YBEE1D96JPXRQ/IMG_2285.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685966215-HEJOHMRASIKODJYN2QCJ/IMG_2578.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685742485-DIWD24CXVAQA90AG8YVP/IMG_2554.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542686172505-XD7IJP18SV9N0BM8SAVS/IMG_E2491.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1544313350820-PG9P7ULIV48JETEJAPGT/IMG_2289.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542684952823-NWYTYTUJ55WLJT1YQOZU/IMG_2431.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685896897-ZDJHLRN7DZAMYBJZ3F47/IMG_2586.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542684698124-5GMSA9PTUV7YF1G2IRFM/IMG_2286.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542685148907-ZKZSDRLRW5697UHM196Q/IMG_2439.jpg Workshop - Downdraft Table https://images.squarespace-cdn.com/content/v1/57f92388f7e0abb4aef5bd50/1542686394944-17QCH32EAAQSPG3OEBWI/IMG_2612+2.jpg Workshop - 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