Installation of Instrument Panel & Nose Fuel Tank in Champ

[Robert Henley]

Even though I have my project for sale, I am continuing to work on it. If I can find someone to help me onsite through these issues I am having, I’ll keep the project and finish it. I have someone who says they will help, so I may be on my way to completion.

I am trying to understand how the instrument panel is fastened to the fuselage. I couldn’t find any drawing on my DVD showing the installation. The tubing running horizontally across the front of the cockpit has holes in it that are fore & aft. Is that where the bottom of the panel mounts? How is the top of the panel secured?

If anybody has pictures showing the fastening points, please post them so I can better understand what I need to do.

Also I seem to recall someone posting a website that had all kinds of instrument panel layouts for Aeroncas, but I can’t find any reference to it. If somebody knows about such a site, please let me know.

Is there any material placed between the nose fuel tank and the wood panel below the tank? It seems like a rubber mat between the two would help in protecting both the tank and the wood.

Regards

[David Johnson]

Robert, don't give up. There are lots of guys here that will help you any way they can. The instrument panel bottom attaches to the cross tube with PK screws I think. If I remember correctly, there is a vertical angle welded to that tube in the middle to hold the panel at the correct angle. The fuel tank sits directly on the wood. Doesn't hurt a thing. I don't have photos, but can get them in a day or so if needed. DON'T GIVE UP! David J.

[Robert Henley]

David

Thanks for the encouragement. The instrument panel that came with the project is fiberglas and not cut out at the ends. The WagAero panel is metal and cut out at the ends. I'll probably buy it to make my life easier.

Robert

[Dennis]

Robert,

I have an instrument panel that has not been used other than a template. At one time I loaned it to Wag. All the holes are correct and in the right place plus the small mounting holes are there. I stretched it a little to get it to fit over the blank Wag panel. I can make you a template if you like.

Dennis

[Paul Agaliotis]

Robert,
You are correct that the bottom of the panel secures to the cross tube. The top is secured to the boot cowl. I believe a piece of fender welting is placed between them. The vertical piece in the center of the panel that David J is talking about sometimes gets cut off to install a Spitfire horizon or some other crazy instrument.
Keep plugging away at it. There is only about 100 parts in the fuselage, put in one a day and it's done in 4 months. Give me a call if you get stuck.
Paul

[Robert Henley]

Robert,

I have an instrument panel that has not been used other than a template. At one time I loaned it to Wag. All the holes are correct and in the right place plus the small mounting holes are there. I stretched it a little to get it to fit over the blank Wag panel. I can make you a template if you like.

Dennis

Dennis

Thanks for the offer. Right now I am thinking my panel layout will be custom. Therefore the WagAero panel probably makes the most sense. If I change my mind I will take you up on your offer.

Thanks

Robert

[Robert Henley]

Robert,
You are correct that the bottom of the panel secures to the cross tube. The top is secured to the boot cowl. I believe a piece of fender welting is placed between them. The vertical piece in the center of the panel that David J is talking about sometimes gets cut off to install a Spitfire horizon or some other crazy instrument.
Keep plugging away at it. There is only about 100 parts in the fuselage, put in one a day and it's done in 4 months. Give me a call if you get stuck.
Paul

Paul

My vertical piece is just a nub. The old panel was a flat piece of aluminum and probably had a gyro in that spot.

My entry step is also missing. It was cut off at the bottom of the fuselage tubing. It had a kludged step of bent metal. I want to replace it. Has anyone ever fabricated one from the drawings? I thought I would call WagAero to see if they would do it. I thought I could get a piece of tubing with OD = to the ID of the step then slide it in to the old step tubing, bolt it in and then slide the new step onto it and secure it with bolts. Too much has been done to the fuselage to weld it on.

Regards

Robert

[David Johnson]

Robert, just a note about the step installation. I know you can buy the step from American Champion. Don't know about Wag. The streamline tubing on a Champ is 1.349X0.571X0.035. A Citabria is 0.049 thick. Not sure the 0.035 is even available. This bends real easy with a fat boy like me. The new airplanes from American Champion have a 0.063 or so brace from the bottom longeron about 2-2.5 inches long welded on. Looks like a good idea. I am going to put one on the next airplane I have to work on. David J.

[DC Krog]

Don't drill any holes in that cross member tube. The bottom of the instrument panel is bent to wrap around the cross member tube and there should be a hole where the engine primer goes through. The Engine Primer nut is what hold down the instrument panel to the cross-member tube. The top of the instrument panel is secured to the boot cowl with 6 number 10 screws with elastic stop nuts. It is a simple design and very easy to work under the instrument panel. Try to get some photos of other members instrument panels for reference.

[Robert Henley]

Don't drill any holes in that cross member tube. The bottom of the instrument panel is bent to wrap around the cross member tube and there should be a hole where the engine primer goes through. The Engine Primer nut is what hold down the instrument panel to the cross-member tube. The top of the instrument panel is secured to the boot cowl with 6 number 10 screws with elastic stop nuts. It is a simple design and very easy to work under the instrument panel. Try to get some photos of other members instrument panels for reference.

Unfortunitely holes have already been drilled in the cross member tube. I'll check out the engine primer location to see if it is still there. I hadn't planned on installing a primer.

The top of the panel is secured to the wraparound cowl? I hope I can see some pictures on how the panel is installed. So far none have been posted.

Regards

Robert

[Dennis]

Robert,

Here are a couple of pictures including hanger dust. Hope this helps. Note the primer nut which matches a plate behind the panel and and the black screw just above the N number which attaches to a vertical bar behind the panel as well as the screws on top. This is what everyone is talking about.

Good luck, Dennis

[Robert Henley]

Thanks Dennis, that really helps me. What model year is your Champ?

Robert

[David Johnson]

Dennis, you got photos posted FAST! Robert, keep hollering if you need anything!(PS all the Champs are the same up till the late 50's) David J.

[MikeB]

Dennis,
Is that the heater outlet on the left side of your picture (white thing)? If so, different than most Champs. It seems that project should be flying by now as the wings were being covered some time ago. One other question, seems you have the Wagner 0200 STC. Did you build the mount or???? Starter type??

thanks,
MikeB

[Dennis]

David,

My hanger is in my back yard. It took me longer to figure out how to post the pictures.

Mike,

Pardon me while I pull the knife out of my back:-). I swear I will start back on the wings this week.

The white heater is not original?????? Must be a problem with the photo, or........ ?

Finally a question I can answer! Yes, I built the mount from Buzz's 0200 STC. I took the old 65 HP mount and set it on 1" spacers and built a jig around it. Hell, when I fly it for the first time, it may fly cockeyed. But at the rate I am going on the wings, it may take a while. Here is a picture of it:



Dennis