|
CLICK HERE Or On Your Back Button To Return To Previous Page
Ideas for building your panel. Follow along as I put together a basic panel for a Zenith CH701. The panel will be fashioned into three sections that can be removed for service after the airplane is finished. A lot of thought should go into your panel before you drill the very first hole. I do a full size drawing using AutoCAD, then print it out in full scale so eventually it will act as a drilling and cutting template. Here I will take
you thru the process of doing all the metal work, one step at a time. Broken down into small bites, it is really quick and easy to do yourself.
Custom Design & Build For Mark & Bob Bybee In Southern Illinois
CLICK ON ANY PICTURE TO SEE IT LARGER
|
 |
Here you see the finished drawing. It is printed to full size, the dimensions are checked, and it is laying on top of the panel to make sure it fits properly. A lot of time has been put into making sure all the instruments, switches, breakers, etc... are located exactly where you want them to be. This drawing can be created using your electrical schematic diagram, flight controls, and flight instrument list. Size
and location depends on the exact instruments, radios, switches, and indicators that you choose to use. |
 |
Now that the template has been check for fit, it is cut into the three separate parts that will be use as templates for the three individual panel pieces that are cut from .025 6061 T6. These pieces will become the removable panel sections. They will be fitted to the original Zenith panel. Each panel will be held in place with Nut Plates and 6-32 Stainless Steel Screws. As all drawings are full size, they will now be able to serve as
drilling and cutting templates for the panel sections. |
 |
The next step is to use the templates to cut out the three aluminum panel sections. Carefully mark around the outside of the template and then cut and trim the panels to fit on to the original Zenith panel. Note that a space has been left at each end for the trim pieces that will be put into place before the panel is mounted in the airplane. Carefully measure and find the center of the main panel, and make a mark on the panel bottom frame. |
 |
 |
As both the throttle and choke controls extend through the panel and will remain in place when the left panel is removed their areas need to be taken from the main panel and mounted separately from the panel itself. |
 |
Now using the Left Panel drawing as a template I make marks around the perimeter where I will be putting the mounting screws. Nothing special about the spacing, just random but placed so that they will not interfere with the mounting holes for the various panel components. I carefully drill 4 #40 holes and cleco the template to the panel. Now using a center punch I mark the locations of the remaining mounting holes into the panel. |
 |
Using the same technique as in the previous frame, I mark the other two panels, center punch the marks and using a #40 drill finish the perimeter mounting holes in the remaining two panels. Also note the Throttle and Choke plates have been removed and await their mounting. |
 |
I now cleco the templates back on the panels. Note that all the round objects have a center mark already on the drawing. That is done with AutoCAD. For the remaining square objects, I find the center point by drawing "X" lines across the object. I now carefully center punch all the centers on the template, making final the location of each component on the panel. I do all three panels the same. I also mark the center
of the Throttle and Choke plates at the same time. |
 |
Here I have drilled all the marked points with a #40 drill. As I will be using a CNC Mill to cut most of the openings in the panels, the drilled center points will be used as references for the Milling operations that will come later in the process. For this particular build the center panel will be used to mount a Lowrance 2000c GPS. That work will be done by the aircraft owner after my work on the Left and Right panels is finished. |
 |
 |
This step is probably one of the most critical. It is time to mate the panels to the original Zenith panel. Start by making sure the center marks on both panels are aligned. Check end clearance for mounting brackets. Carefully line up the panel outer edges then drill and cleco it together. |
 |
Here the drilling with a #40 drill continues. With the main panels in place, the Throttle and Choke panels are centered and drilled for mounting to the main Zenith panel. Proper size holes for the cable mounts will be drilled after all has been assembled. Care must be taken here to assure that all the parts are in good alignment. It is now time to finish drilling all the holes around the perimeter of the panels. |
 |
 |
Now using a 11/64 drill bit, carefully drill out ALL of the panel perimeter holes, replacing each silver cleco with a black cleco as you move around the panels. Do not drill out the holes in the Throttle and Choke Cable plates! The 11/64 inch holes are the size of the Nut Plate that will be installed. |
 |
Here the top panels have been removed and the Nut Plate mounting holes are drilled into the Zenith panel. Everyone has their favorite way of drilling Nut Plates holes. I first put the nut plate into the 11/64 hole, align it with my finger and drill a #40 hole thru the Nut Plate lug into the panel. I then cleco the hole just drilled and drill the hole through the other mounting hole. Looking left of center, you can see the upper and lower group
of four #40 holes for the mounting of the Throttle and Choke plates to the Zenith panel. |
 |
 |
This is a back and front picture of how the panel looks after using a Spring Back Dimple Die to process the panel holes for flush riveting. The 4 holes in a square are for riveting the Choke plates to the top of the panel. |
 |
 |
The next big step is to get out the trusty Dremel Tool and cut the openings in the Zenith panel. Once opened up you can now finish the Dimpling of the holes that could not be reached. This is by no means the final opening You will need to do some additional trimming as the instruments are installed. |
 |
 |
Here you see Nut Plates installed, both back and front. Using 3/32 flush head rivets you can see how nice it all comes out. The right picture is the Zenith panel top with the Throttle and Choke plates riveted into place. |
 |
 |
The Left picture shows the CNC Mill cutting one of the 3 1/8" instrument openings in the panel. The Right picture shows the left panel with all of the instrument openings cut and drilled for instrument mounting. The neat thing about using the CNC is that the openings are perfect and identical. |
 |
 |
Here is the Left and Right side panels, rear view, with all the openings CNC cut and ready to mount the instruments, breakers, radios, intercom, etc...
Remember to click on the pictures to view them much larger. |
 |
Here are the finished panels laying over the greatly modified Zenith Panel. The center area is where the builders are going to install their Lowrance 2000c GPS. As they will be doing a custom paint job on the panel, all CNC cutting was done on the back side to preserve the factory finish beneath the protective plastic coating.
After Mark and Bob finish installing the instruments and other items in the panel I hope to have additional pictures, including
when it is installed in their beautifully constructed Zenith CH-701.
|
Here is the final result as Bob and Mark have their CH701 Panel Installed
  |
|
|
|
| Well there you have it folks. A Zenith CH-701 panel all cut out and ready to mount your goodies. Hopefully this pictorial story will help you to design and build your panel. It is really quite a simple process, once you break down the steps into bite size tasks. This particular design has a center Throttle and Choke as they are doing a dual stick build. Making the panel sections removable will save a lot of "laying on
your back" trying to troubleshoot any future problems you may have with the panel, or just doing an upgrade or changing out an instrument. I think this is a really good technique for use in any Zenith Airplane you may be building. You don't need to make the top panel cover removable, or build in any access openings for rear panel access. Just take out a few screws, tip the panel out, and do your thing. It could not be a whole lot easier, no matter how hard you try! |
| |
TIME FOR THE COMMERICAL
|
 |
Contact me if you need help with designing and getting your panel started. I will be happy to quote you a price for the work you would like to have done. I can do as little or as much as you would like. From initial drawings to a finished wired panel. I can do the same kind of a layout, CNC cutting the openings in your original Zenith panel. You may be surprised at how reasonable my price will be to cut all of your panel openings with
CNC accuracy. Or if you wish I can produce a full size AutoCAD template for you to build your own panel from your equipment list.
Pricing starts around $100.00 for panel design and cutting.
|
| mykitairplane@mrrace.com |
Please contact me with your needs and ideas for a price quotation.
|
 |
George Race
Race Consulting
Builder & Test Pilot
Zenith CH-701 N73EX
Click Here -- To Ask Question Or
Leave Comment
|
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)