Template: InstrumentPanel

I decided to make my instrument panel from carbon fiber, primarily to avoid riveting angle to the profile of the aluminum version. I like the Super Cub style panels that have a formed flange for which to attach the glare shield and boot cowl. The best way to do this was to do it with carbon fiber because it can be molded.

I build my mold from 3/4" MDF and used 2 layers. The top has the cutout shape of the panel. I used Bondo to form a fillet around the perimeter, and sanded it smooth, then primed and wet sanded. The next step is a glossy top coat to get the best carbon layup finish.

All Garmin panel...getting excited.

Panel layout

This is TBD.

Panel Construction

Because I want a smooth, filleted flange atop the panel like a die-pressed factory Cub panel for attaching the glareshield, I figured one way to make that happen is to use carbon fiber. I created a mold from MDF based on the kit panel shape and added a 1/4" fillet with Bondo. I then routed it with a rounded 1/4" bit to make a perfect fillet. Several coats of primer and wet sanding to get a smooth finish, and I have a nice mold.

The next step would be using a vacuum infusion method to press the carbon fiber layup.

Some years later though, with the advent of easy laser cutting, I've determined that it's hard to beat an aluminum panel and will likely just go that route, using 6061 and welding my flange on instead of giving up 1/2" to use riveted angle.