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Kupe's Zodiac 650B
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Date:  1-29-2016
Number of Hours:  2.50
Manual Reference:  
Brief Description:  Instrument Panel 6 - Glove Box 4

Finished off the glove box today by riveting everything together and checking one last time for fit through the combined instrument panel and template. Not surprisingly, the greater tightness of a riveted assembly (vice clecoed) required me to perform some final filing through the panel and template so the door would open and close freely. Glovebox complete except for final installation to the instrument panel, which I will do after the panel is installed in the airplane.

Next I returned to the final cut outs on the insturment panel: radio, intercom, throttle mount (2), and flap switch.

The radio and intercom cutouts were a challenge. I have the (fairly) new Dynon radio/intercom and they both have somewhat non-standard openings so it was slow work to cut them out then match them to the template. Using a combination of Olfa knife for the longer cuts and Dremel for the shorter ones, I was able to get the openings close to the template dimensions. After that it was a matter of some detailed filing to get them to their final size.

I also drilled out holes for the 2 throttles (reminder: my plane will have a single, center stick, so there will be throttles on the left and right sides of the instrument panel) and the flap switch.

In the third image below you can see how the instrument panel will look when completed. From left to right, you can see the pilot's throttle, above it is the flap switch (co-pilot/passenger doesn't get a flap control!), left eyeball air vent, Dynon Skyview system, VHF Comm radio, stereo intercom, power panel below the radio/intercom (with common switches and circuit breakers), glovebox, right eyeball air vent and a hole for the right throttle (which I didn't unpack for this picture).

Now for the hard part - all the wiring and connections located behind this simple-looking panel!
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Completed glovebox, closed and latched.

Completed glovebox, closed and latched.

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Completed glovebox showing doorstops and interior rivet pattern.

Completed glovebox showing doorstops and interior rivet pattern.

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Fully cut out instrument panel with most of the pieces temporarily in place.

Fully cut out instrument panel with most of the pieces temporarily in place.

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