AndreiC Posted Thursday at 02:37 PM Report Posted Thursday at 02:37 PM I got a crazy idea, and I am sure I'll be told off soon about this. But hear me out. My plane (1970 E) has the standard six pack with modest avionics (JPI 700 engine monitor, GNS430W/KX155/KT78, original engine instrumentation). Nonetheless I am happy with their functionality and don't want to change anything. However, I dislike the way the whole thing is laid out, it all look very scattershot; rearranging things would make things better. My question: what would it cost to have someone cut me a nice one piece panel that I would design? And how much would it cost to have it installed? Can I do some or most of the work myself, under supervision of an A&P, or do I need an avionics shop for this? Has anyone done anything similar to this, or is this a crazy idea?
47U Posted Thursday at 04:05 PM Report Posted Thursday at 04:05 PM 1 hour ago, AndreiC said: My question: what would it cost to have someone cut me a nice one piece panel that I would design? And how much would it cost to have it installed? Can I do some or most of the work myself, under supervision of an A&P, or do I need an avionics shop for this? An avionics shop isn’t mandatory, but they would be the best resource to make your transformation successful. If you can do the CAD part, cutting a new panel might run only a few hundred dollars. If you hand over a panel sketch layout that needs to be programmed then that will be more. If you do the work, you need to have basic sheet metal experience mounting trays and such in a blank panel. If you can relocate the avionics, circuit breakers, etc., within the limits of their harnesses and pitot static connections, I would think your A&P would work with you. Many have been successful, but it’s not for the faint of heart.
MikeOH Posted Thursday at 04:07 PM Report Posted Thursday at 04:07 PM I've thought about the EXACT same thing! So, I'm interested in the responses, too. I've had parts of the panel apart under the supervision of an A&P, so I don't think that is going to stop us. My impression, however, is that there is a whole lot of stuff to disconnect and actually moving the position of instruments is going to, IMHO, run the MIF (maintenance induced failure) factor to unacceptable levels for my comfort. Obviously, moving anything related to the pitot/static system is going to require the inspection/sign-off from a shop. I do believe some have done overlays that look decent...but, of course, that doesn't relocate anything. 1
MikeOH Posted Thursday at 04:10 PM Report Posted Thursday at 04:10 PM 3 minutes ago, 47U said: Many have been successful, but it’s not for the faint of heart. BINGO!! That's what has stopped me. Frankly, while I'm not looking to upgrade avionics, the thought of even a qualified shop tearing my entire panel apart for a major upgrade makes me shudder. Plenty of reports of previously working items no longer working after panel surgery!
DCarlton Posted Thursday at 04:11 PM Report Posted Thursday at 04:11 PM Just guessing but if you already have a six pack, you might not have to move any of the instruments or radios much at all. Minimize the rearrangement and it might not be that difficult. You might get lucky and not have to rewire or replumb much. I've thought about doing it but I'm not sure the juice is worth the squeeze. 1
MikeOH Posted Thursday at 04:12 PM Report Posted Thursday at 04:12 PM Just now, DCarlton said: I'm not sure the juice is worth the squeeze. Well put!
LANCECASPER Posted Thursday at 04:30 PM Report Posted Thursday at 04:30 PM @Aerodon is good at this type of thing
Igor_U Posted Thursday at 05:02 PM Report Posted Thursday at 05:02 PM Few years ago I used company in ATL area that is now part of Xiometry. I created the CAD file of the LHS and RHS panel and used their online quote process, selected Al Alloy (7050 or 2024) and got the waterjets parts. If I recall correctly, it was about $300 per panel. https://www.xometry.com/ Please check their website for current details and quite process. I recall the old company (Big blue saw) had a web based CAD software you could use but I never did try that since I use CATIA for work. I did the install myself with the IA oversight. Good luck.
Yetti Posted Thursday at 05:42 PM Report Posted Thursday at 05:42 PM depends on how much you move things around. There are two metal tube that run fore and aft from the centerline behind the panel that dictate what can go in some spots.
AndreiC Posted Thursday at 06:04 PM Author Report Posted Thursday at 06:04 PM Well, since it seems there has been at least one person who did this @Igor_U, was the juice worth the squeeze? Can you perhaps share pics of the after results?
Aerodon Posted Thursday at 07:59 PM Report Posted Thursday at 07:59 PM 5 hours ago, AndreiC said: I got a crazy idea, and I am sure I'll be told off soon about this. But hear me out. My plane (1970 E) has the standard six pack with modest avionics (JPI 700 engine monitor, GNS430W/KX155/KT78, original engine instrumentation). Nonetheless I am happy with their functionality and don't want to change anything. However, I dislike the way the whole thing is laid out, it all look very scattershot; rearranging things would make things better. My question: what would it cost to have someone cut me a nice one piece panel that I would design? And how much would it cost to have it installed? Can I do some or most of the work myself, under supervision of an A&P, or do I need an avionics shop for this? Has anyone done anything similar to this, or is this a crazy idea? I do this in my spare time for customers, my side hustle to fund my aviation habit. The later Mooneys are easier to do, I have several versions of OEM panels to start from. Most of the work is in the design and CAD, then it is relatively inexpensive to get a template cut by one of the commercial services. I always do the final on my AXYZ machine to make sure it is aviation grade aluminum and so I can test fit instruments before shipping. Sometimes I do additional work like countersinking, painting and even labelling. The first time for any panel is time consuming and iterative. It's hard to get it right the first time and it gets frustrating for me when I don't get good customer feedback o moving things around. I'll suck up a bit of the learning curve on 'new designs', I'll make it up later on repeat orders. I'm pretty good on M20J/K and later panels. I'm looking for a M20C-F project to expand my portfolio. You need to work with your local guy to get it installed and signed out. He will advise what parts you can help with. There is a lot of labour in taking things apart, and some detailed knowledge is required to remove old unwanted stuff. Aerodon 2
Igor_U Posted Thursday at 08:31 PM Report Posted Thursday at 08:31 PM 2 hours ago, AndreiC said: Well, since it seems there has been at least one person who did this @Igor_U, was the juice worth the squeeze? Can you perhaps share pics of the after results? I'm sure it was done on a number occasions as I remember reading about. Anyway, attached are pictures for LHS and RHS panel. Unfortunately, I don't have final CAD files I created as I used a (former) work computer. 1
ArtVandelay Posted Thursday at 08:34 PM Report Posted Thursday at 08:34 PM Be prepared for some breakage, our planes are old, in my case the plastic pitot static tubing was brittle and it all needed to be replaced.
pirate Posted Thursday at 09:37 PM Report Posted Thursday at 09:37 PM https://superioraircraftcomponents.com
AndreiC Posted Saturday at 11:23 PM Author Report Posted Saturday at 11:23 PM @Igor_U That panel is beautiful, that is the kind of thing I was hoping to get to... How many hours of work on your part do you estimate that was to install it (not counting the CAD design time)?
00-Negative Posted yesterday at 05:39 PM Report Posted yesterday at 05:39 PM 17 hours ago, AndreiC said: @Igor_U That panel is beautiful, that is the kind of thing I was hoping to get to... How many hours of work on your part do you estimate that was to install it (not counting the CAD design time)? I just did my pilot side. I used the CAD files available in the downloads section. I sent the file unchanged to https://sendcutsend.com/ and for around $120 I had a powder coated panel at my doorstop within a few days. Process probably took me probably 30 hours. I spent a lot of time removing old wiring harnesses for old radios, marker beacon systems, etc that are no longer in the plane. I needed to replace oil temp probe and EGT gauge. I found my 6lb backup navcom tray wasn't properly secured and easily moved up and down, so I fixed that. I replaced old vacuum tubing, scat tubing, pitot & static tubing. Rerouted random ground wires and spent a lot of time cleaning up and routing and securing everything behind the panel. Now it doesn't look like a couple of 6 year olds put my plane together. The only maintenance induced failure I encountered was when I dropped my freshly overhauled directional gyro on the ground. I still have a few minor things I need to do on the panel. Worth it. And future upgrades (G5s, JPI edm 900) will be much easier. Here are before/after pics. You can see the new panel makes my plane much faster. -David 2
Echo Posted yesterday at 06:04 PM Report Posted yesterday at 06:04 PM Hendricks Engineering did my first M20E Pilot side. They did very nice work. Those panels looke great here. That lighter color is really tasteful Igor. Love it.
Igor_U Posted 7 hours ago Report Posted 7 hours ago On 10/25/2025 at 4:23 PM, AndreiC said: @Igor_U That panel is beautiful, that is the kind of thing I was hoping to get to... How many hours of work on your part do you estimate that was to install it (not counting the CAD design time)? It's hard to say but RHS panel took longer due to complete rewiring and adding new circuit breakers above the original ones. LHS panel install took probably one full weekend once the cutting and powder coating was done (Seattle powder coating). This requires some downtime in order to remove the old panel and figure out the proper layout and to assure the clearance to the structure under panel. I've done the LHS panel while waiting for the engine from the factory. I chose the off white shown as I prefer light colors and contrast provided with instruments. I used dry transfer lettering and clearcoat on RHS panel which looks great. LHS panel done later was with some self adhesive foil that you can print on and stick on the panel but I wouldn't recement them. Make shore that mounting holes are properly located and clearance holes so you can position panels correctly. At that time I used a LASAR kit for installing the flat panel. Heather did some research and provided standoffs/spacers (see below) and Lord rubber mounts for the panel. Price was less then $50.0 but some of the spacers didn't have a adequate length to place the panel to the angle required for the turn coordinator so I purchased few at McMaster Carr. I think even rubber mounts can purchased there... Some rewiring was needed as instruments have Nulite underneath the panel. Those were wired to the original pot at the ceiling and worked quite well. CAD work and selecting hardware and such was easy for me but I design airplanes for living. it shouldn't be that difficult providing you have an access to CAD software but perhaps it's the best to get the panel from a pro and install it yourself. One thing to be aware, original secondary structure needed some moderate trimming to clear the ASI al the way at left top corner. If you look at the first picture posted by 47U, it will be self-explanatory. Good luck.
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