Reworking radio trays

[Martin S.]

Evening gents,

anybody a good idea on how to rework radio trays (this frame that holds all the avionics). Mine are full of holes. Having a small avionics upgrade, the old holes dont match, if I insert new ones, they will most likely interfere with the old ones, which is sub-optimal.

Greets,

 

Martin

Edited November 24, 2023 by Martin S.

[N201MKTurbo]

When I redid my avionics in 2017, mine were worse than yours. I just made new ones.

[PT20J]

Time to buy new material and start fresh. That's what we did.

[Martin S.]

5 hours ago, PT20J said:

Time to buy new material and start fresh. That's what we did.

Thanks for your answer. You mean you ordered the fram new at Mooney? Or did you weld some fresh profile to the frame?

 

[N201MKTurbo]

Get some sheet metal, bend it into a big U shape and cut holes for the radios, buttons, lights etc… paint it black and call it a new radio rack.

I used an air nibbler than a hand nibbler then files to make the big radio holes.

[PT20J]

On mine the installer ordered some material that the vertical rails are made from, cut new rails to length, drilled them for the new trays, riveted the trays into the rails on the bench and installed the entire stack in the panel.

[A64Pilot]

I’ve not looked in a while, but aren’t they just simple 90 degree extrusions? If not is there any reason an extrusion won’t work?

Usually an extrusion is stiffer than pretty much any sheet metal that you can form yourself, and of course as it’s already formed easier to just cut.

IF I were making a new panel, I’d do what I did with my Maule, that is cut the existing panel out, leaving about a half inch lip all around, in this lip install nut plates, then cut the new panel from a decently thick piece of sheet metal that fits over the lip and is installed by screws. Graduate level, install everything on the bench and connect with cannon plugs, then complete panel removal with all instruments is a simple 5 min job and everything can be worked on on the bench.

Then in the future in order to work on anything behind the panel, simply sit in the seat, remove the screws and the panel comes out enough so that everything behind the panel is easily accessed with you still sitting in the seat, no laying on your back on the floor trying to reach up.

As the radio stack is in the middle, of course the left and right panels are each separate pieces.

I didn’t come up with this, the Thrush crop duster is built this way. I don’t understand why it’s not common practice.

[PT20J]

Mine in a 1994 J are extrusions.

[N201MKTurbo]

In my 77 J there is no room for extrusions. It looks just like the OPs picture. The racks are attached to the instrument panel at the top and the steel tubes at the bottom. The two radio racks touch each other and you can only have flush rivets on the radios. I had to double flush some of them. It is an exercise in creativity, contortion and blood.
 

I helped with a 1980 Rocket 231 and we used aluminum angles. I used aluminum angles for my Cessna.

[ArtVandelay]

On mine the installer ordered some material that the vertical rails are made from, cut new rails to length, drilled them for the new trays, riveted the trays into the rails on the bench and installed the entire stack in the panel.

That’s what mine did too, the vertical rails weren’t sheet metal, the look pretty robust, maybe 1/8” thick.

[65MooneyPilot]

I have https://www.radiorax.com/

they work well and when you change radios you just slide the mount nut to match the can. Not cheap but it is a one time deal. 

[Fly Boomer]

2 hours ago, 65MooneyPilot said:

I have https://www.radiorax.com/

they work well and when you change radios you just slide the mount nut to match the can. Not cheap but it is a one time deal. 

Their AML covers C, B, and P -- no M.

[65MooneyPilot]

I am sure you can have it field approved. It is just an aluminum channel screwed into the instrument panel.

[N201MKTurbo]

56 minutes ago, 65MooneyPilot said:

I am sure you can have it field approved. It is just an aluminum channel screwed into the instrument panel.

Not on the 77 J. It won’t fit. The only way without a completely new panel is what the OP shows.

[StevenL757]

On 11/23/2023 at 6:28 PM, Martin S. said:

Evening gents,

anybody a good idea on how to rework radio trays (this frame that holds all the avionics). Mine are full of holes. Having a small avionics upgrade, the old holes dont match, if I insert new ones, they will most likely interfere with the old ones, which is sub-optimal.

Greets,

Hello Martin,

If you haven’t already done so, ask your shop whether they would be able and willing to fabricate a new rack.  The rack on my first Ovation looked like yours and I had to have a new one made, as there were simply too many existing holes with no room to add new ones.  My shop has an excellent sheet metals guy, and they made me a new one for a very reasonable price.

Appreciate you’re in Germany; however, am happy to put the two of you together to discuss your needs if you think it will be helpfuI.  I have no doubt that they will be happy to help you.

Regards, Steve

[M20F-1968]

I do not like the fact that trays are riveted onto these sheet metal supports.  I designed my panel with vertical aluminum rails about 1/4" thick.  These run from the upper instrument panel bow to the lower horizontal bar.  The trays are screwed into them.  That way, the radios and trays can be removed from the front of the panel.

John Breda

[Martin S.]

Update in this regard. I ended up fabricating a new left rack. The right one can be re-used. As was stated somewhere else, the clearance-wise critical location (at least for mymy serial num 24-0520) is between the left and right instrument rack. In case of two instruments located next to each other (at same height level), one in the left one in the right rack respectively, it is impossible to rely on screws for mounting the trays. There is simply not enough space, rivets are required. For all other cases, I managed to rely on screws.

[Medicpilot]

On 12/1/2023 at 3:45 PM, Martin S. said:

Update in this regard. I ended up fabricating a new left rack. The right one can be re-used. As was stated somewhere else, the clearance-wise critical location (at least for mymy serial num 24-0520) is between the left and right instrument rack. In case of two instruments located next to each other (at same height level), one in the left one in the right rack respectively, it is impossible to rely on screws for mounting the trays. There is simply not enough space, rivets are required. For all other cases, I managed to rely on screws.

Do you happen to have the specs for this stack you made?  I am trying to remake mine as well, but if I could have it built before removing mine that would be ideal.  0.100" Aluminum?  

[N201MKTurbo]

47 minutes ago, Medicpilot said:

Do you happen to have the specs for this stack you made?  I am trying to remake mine as well, but if I could have it built before removing mine that would be ideal.  0.100" Aluminum?  

I recall I made mine out of 0.032 2024T3.

[N201MKTurbo]

FWIW, when I made mine, I made the sides go back about 3” so I could put some rivets at the back of the sides. It made a stiffer assembly and it didn’t require any back straps. 
 

I can afford the ounce or two of aluminum.

[Martin S.]

Do you happen to have the specs for this stack you made?  I am trying to remake mine as well, but if I could have it built before removing mine that would be ideal.  0.100" Aluminum?  

It’s 1mm thickness. Still got the old tray (that served as model). Can take some measures tonight, if that helps.

Can take some measures if that helps.


Sent from my iPhone using Tapatalk

[Martin S.]

On 11/20/2025 at 7:45 PM, Medicpilot said:

Do you happen to have the specs for this stack you made?  I am trying to remake mine as well, but if I could have it built before removing mine that would be ideal.  0.100" Aluminum?  

Here u go:

[Yetti]

https://radiorax.com/