Total Build Time: 1021 Hours.
With my work under the instrument panel about 99% complete (fuel tank, electrical wiring and pitot/static/LRI routing done) I decided it was finally time to finish off the glareshield.
Just before doing that, I finished the routing and installation of my radio intercom plugs, which are located high on the right side of turtledeck former #1 (just behind the passenger’s head.) These are installed with insulating washers to isolate the plugs from the grounded metal of the airframe.
Next comes the glareshield, which is riveted/bolted in place and ready to cover.
Notice in the above picture that I added some small strips of aluminum above the instrument panel to allow for a nice finishing trim that I’ll detail later in this post.
I had ordered the Sonex upholstery kit from sonexaircraft.com, which included an piece of fire-resistant fabric identical to what covers the rest of the upholstery, roughly cut to the shape of the glareshield.
Here is the fabric loosely placed into position on top of the glareshield:
Next I masked off the instrument panel in preperation for the application of adhesive. Per some other builder recommendations, I used Permatex 27828 Body Shop Heavy Duty Headliner and Carpet Adhesive.
After cutting the fabric to fit, I applied the adhesive to the glareshield and pressed the fabric into place in 3 stages: center, left, then right. This would allow me to press any bubbles to the outside of the material as I worked. This entire application process took about an hour.
With the center aligned and pressed into position on top of the adhesive, I applied adhesive and pressed the fabric onto the left side:
The right side was done in the same manner.
Next, I tucked about 1/2″ of excess fabric covering around the strips above the instrument panel, then installed some black automotive door-edge protector to the edge of the strips. I bought this edge protector from the local auto supply, and it includes an adhesive within the protector that activates when pressed into position.
I’m very pleased with the end result, and just hope that the fabric will hold up under the beating sun once my plane sees daylight for the first time!
Here are a few various photos of the glareshield with my ipad mount installed, and a view behind the instrument panel.
