What I did was 1) cut out three large holes, one in each side portion
of the panel (the whole area except for a 1" border and in the
main panel, one large hole (with a 1" border on top and bottom) just left of
center. For each of these wholes I made a 6061T6 plate 0.050"
thick that covered the section in question and each are mounted with 8 nut
plates to the panel. Seems to be pretty rigid, but do not know how much
force each experiences. The design was so that I could easily remove the 8
screws and pull that entire panel section forward and get at any wires that
may need fixing.
I also cut a center portion of the glare shield, installed a hinge and many
nut (5 across the front and 4 on each side) plates along with extra
reinforcement on each side and stiffener panels on the raise able portion of
the glare shield so that I could unscrew and raise the glare shield to get
at wiring behind the center and right portions of the main panel. All nut
plates are about 2" to 3" apart on the glare shield panel. My fear is that
I may have compromised the integrity of the panel, even though I tried to
strengthen areas that I thought might require stiffening.
You will note that I have been a freek about ease of accessibility behind
the panel. I can get at everything behind the panel and have room for
future growth.
I know the above may sound confusing so I have posted 3 pictures on the
Rebel Panel section of the builders site.
I will taxi the plane tomorrow to see if I note any power surges.
I appreciate your comments, Bob
-----Original Message-----
From:
mike.davis@dcsol.com [mailto:
mike.davis@dcsol.com] On Behalf Of Bob
Patterson
Sent: Sunday, October 11, 2009 5:16 PM
To:
rebel-builders@dcsol.com
Subject: Re: [rebel-builders] Rebel - panel mod.
Hi Gary !
The large holes are ok - IF they had stiffeners around them,
extending out .... Many guys use floating panels for the instruments,
although they are usually just done with oversize round holes,
rather than huge rectangles. Cracks are not that common these days...
as most have the bottom channel. I think Ray had 200 or 300 hours...
Cracks are one issue - there is also the throttle surging,
which you will see as soon as you taxi over rolling ground,
holding the throttle closed. It will still try to jump ahead...
What all that means is that the front cage structure is
flexing & twisting .... not good, long term ... Several
builders on floats have also added 'V' braces to the wing roots,
for the same reason. The bottom channel really helps with
panel space, as, with 2 rows of full-sized instruments, there's
no room left for throttle, mixture, carb heat, trim switch, etc...
Maybe some more builders could post pics of their panels
to FILES. ???
--
......bobp
bobp@prosumers.ca
http://www.PattersonAeroSales.com
http://bpatterson.qhealthbeauty.com
http://apatterson2.ordermygift.com
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-------------------------------orig.-------------------------
On Sunday 11 October 2009 20:44, Gary Gustafson wrote:
I have been reading these ominous emails on 'panel mod' and
I have one question. I cut out several large holes in my panel
and I installed a L channel along the bottom of the main portion
of the panel but did not bend it at the corners and tie them back
into the frame. However, I do not seem to notice any flexing of
the panel (yet). So how long before cracks develop?
-----Original Message-----
From:
mike.davis@dcsol.com [mailto:
mike.davis@dcsol.com] On Behalf Of Bob
Patterson
Sent: Saturday, October 10, 2009 1:08 PM
To:
rebel-builders@dcsol.com
Subject: Re: [rebel-builders] Rebel - panel mod.
Hi Joel !
The gaps at the top should be bridged inside, as the glare shield
is only .020 or .025 - too thin to do much. You can see pics in the
Files of cracks in the glare shield ...
The instrument panel IS structural - it helps tie the cage sides
together, stopping twisting & distortion. that's why it shouldn't
have large holes in it without backing stiffeners.
It's your choice, but I would certainly put a channel ALL THE
WAY across and rivet it (3+) to the verticals. The extra stiffness
IS important, as well as the extra 'real estate'.
I've flown many Rebels without the channel or angles - there
is sufficient flex in the panel that, taxiing with the throttle pulled
full closed, the engine will still surge over bumps & rolls in the
pavement or grass - proof to me that the structure moves !
This becomes more important on floats ....
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