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Rob's REBVAIR Project
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Date:  1-26-2015
Number of Hours:  4.00
Manual Reference:  
Brief Description:  Panel Wiring Part 6

After spending a boat-load of time on the wiring diagrams over the Holidays, and poring over Steinair and BandC online catalogues, I was able to start actual 'physical' work on the panel. To start, you'll see I've built a wood mock-up that reproduces the key features in the plane: the position of the panel relative to the firewall, and the triangular support structure. These are important in assessing the length of the wires and their 'flow' from the switches to the fuse block tray.

I've also added some color to the panel, namely some dark grey rustoleum automotive primer with several coats of a matt finish enamel sealer. Though I can't speak to the durability of the combination, the color and texture came out really well, giving the appearance of powder-coating. Just in case, I'll be protecting key areas with painters tape until final install. The final 0.063" panels will be painted later, also closer to final install.

After spending all that time planning, the wires are actually fairly simple to install: Select the circuit, get the appropriate gage wire and crimp terminal, crimp and insert onto tab on switch, fuse holder, what have you. Then fish the wire through the loom and terminate the other end. In the second image the large arc of wiring is intentional, as I need some excess there to accommodate the eventual 'hinge movement' of the fuse tray. The perforated tray makes placing tie-wraps a snap, and enables the (hopefully) organized routing of wires in that area.
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