8/6/2006
I started by placing the two F-821B baggage door support strips inside of F-821PP to make sure I had their orientation right. They are slightly curved and it isn't immediately obvious how they should be installed. I centered and clamped both to the firewall and F-866. The one that goes over F-866 is a little bit long on both ends so I marked where to cut, removed, cut and re-clamped.
I drilled a few holes in the F-821Bs for keeper rivets then removed them, deburred and dimpled and then riveted them into place. I drew lines on the F-821Bs corresponding to the centerlines in the underlying F-801 (firewall) and F-866 flanges. Then I put the F-821PP skin into position, strapped and taped it down after a bit of nudging and centering.
I then match drilled through the holes in the F-821PP skin through the strip and F-866.
I then cut off the ends of F-803C as per the drawing to allow them to fit over the longerons. I clecoed the F-803C attach flange and the two ends to the two F-802B instrument attach flanges and match drilled all of the #40 holes to final size. Then I deburred the three parts and clecoed them back together. I a centerline in the flange of F-803C.
I cleco'ed the instrument panel to the attach assembly and put it into position in the fuselage. I had to enlarge the notches for the longerons slightly to get the assembly to fit.
I lined up the instrument panel assembly centerline with the holes in F-821PP and drilled starting at the top center. The instrument panel assembly wasn't tight against the skin so I had to drill and install one cleco at a time to pull it in tight.
I couldn't resist the urge so I jumped ahead and made the cutout in the glare shield. I used a die grinder to cut it to about 3/16" from where I wanted it and used a file to about 1/16" and a small ScotchBrite wheel to finish it.
The "instruments" in the picture are what I thought I wanted about 2 months ago. I am not leaning toward removing one of the NAV heads and backup turn-coordinator, altimeter and airspeed and installing a 396 or 496 in an AirGizmos box.