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Safari Helicopter Construction
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Date:  5-2-2007
Number of Hours:  3.00
Manual Reference:  
Brief Description:  Installing Console Switch Panels

The switch console panels will be recessed slightly into the console. I had to fab 2 small angle brackets for the top mounts due to the interference from the forward pod support at the top of the console. The entire right side is removable as illustrated in the 2nd photo below. I had to fit the panels in place to determine the location of the mounting nutplates. Once I had the panels in place it was clear that there was no room for my hands to fit inside the console and mark the locations. I ended up using a couple of small pieces of plexiglass the same size as the panels so I could see where to drill the holes for the mounts. Keep in mind that this is a totally custom console and the only thing common to the plans is the basic shape. This entire console could have been made a lot easier if the plans would have been followed, but I felt that I needed to stiffen it up a bit to prevent the often reported vibrations that result in "instrument blur". The console itself is made from .063" 6061-T6, the 2" angles are 7075-T6 and the panels are made from .125" 6061-T6
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