Tanya & Bryan Duke's RV-6 Panel Rebuild
23 Jul 05: After working nights all week & being in Japan the week before, today was the
first real day Tanya & I got to spend together in the last two weeks. After a lazy morning, we went
to the hangar and got to work. After some wire-routing advise from John Bacon, we decided to change
the way the wiring went from the engine sensors to the firewall. Tanya ran the wire just like Jack
did when he built the plane, but the new way hopefully will cut down a little bit on the heat that
the wiring has to live with. Tanya re-ran the wiring just under the cylinder heads using adell clamps
to keep things in place. She clamped, wrapped & zip-tied everything & put the wiring bundle back
through the firewall. We still need to mount the analog module portion of the AF2500 engine monitor,
but once we do the wiring is ready for it. My only concern is how close the engine monitor wiring is
to the spark plug wires. Everything is shielded, but I still will be keeping my eye out for wierd
readings...hopefully it'll work great.
While Tanya was doing that, I resumed my cutting of the sub-panel. The new hole in the top left of
this picture is for the new location of the EFIS/Lite. I also cut the emergency canopy release
support bracket behind that sub-panel & test fit the radio stack. I made a reinforcement for the
sub-panel using .060 angle aluminum to support that panel so that I can cut the final section out
for the radio stack. I still have to prime & rivet the angle in place, but it looks like
it'll work great.
Back home after dinner (steak, mmmm), we tackled getting all the dust & other imperfections out of the new panel &
old sub-panels we repainted. We tried about 5 different types of polish, but finally got things to
look great by first wet sanding with 600 & 1500 grit paper followed by Meguire's #7 polish and a
polishing wheel. We haven't seen the parts in the sunlight, but I think we're going to be very happy
I called some friends at EAA Chapter 49 & found a place that does reasonably priced silkscreening.
I called the shop & discussed our options. As it turns out, they also do photo etching. The
silkscreening on my old panel was 13+ years old & still was in great shape. Aparently photo
etching is even more permanent. I'm driving to Lancaster, CA on Monday to look at my options & drop
off the panels to get lettered. Hopefully, the panel lettering will be done in about a week so we
can finally start to put things back together.
Panel Rebuild Page
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