New Instrument Pod

[Alan Coats]

I finished making my instrument pod and brackets for it, and I took pictures of it being test-fit on my Bee.

Now that I know it all fits, I can put the final coat of paint on it.

The blank space on the bottom of the panel will get an altimeter and rotor tack.

Alan

[Alan Coats]

I forgot to hit the "Upload" button. I'll try again.

Alan

[gyropilot]

Alan,

Did you make the supports, or did they come with the pod?

Looks very nice!

Thanks,

John L.

[Alan Coats]

Thanks,

I made the pod and the brackets myself. The pod is fiberglass that was laid up over a styrofoam form. The brackets are 1/8" 6061T6. I polished them with some stuff that is supposed to protect the aluminum. I'll see how long it stays shiny.

Alan

[Alan Coats]

Thanks, John.

I made the pod and the brackets myself. The pod is fiberglass that was laid up over a styrofoam form. The brackets are 1/8" 6061T6. I polished them with some stuff that is supposed to protect the aluminum. I'll see how long it stays shiny.

The panel is some crinkle finish plastic I got at the local auto sound system store.

Alan

[scottessex]

Looks good!

[RotoTony]

Good job on the pod! Looks like something you would buy.
Tony

[Screw]

Screw-In

Great job! Looks good.

Screw-Out

[chuter]

Very nice Alan!

[Alan Coats]

Thanks, guys.

I thought that maiking my own pod was one way I could safely save some money.

Alan

[Brian Jackson]

Alan, ya done good my friend! Nice shape, lightweight, cool mounting system... Curious how you formed the consistent radii in your brackets. Looks great.

Thanks,
Brian Jackson

[Alan Coats]

Thanks, Brian.

I clamped a piece of pipe in a vice and bent the aluminum over it by hand. The brackets were trimmed to length after they were bent.

I was surprised how easy it was to get them to match.

Alan

[Brian Jackson]

Originally Posted by Alan Coats

Thanks, Brian.

I clamped a piece of pipe in a vice and bent the aluminum over it by hand. The brackets were trimmed to length after they were bent.

I was surprised how easy it was to get them to match.

Alan

...and the drilling was done after the forming. Nice. I was thinking reverse order. Man I swear I learn more here in one day than I ever could at a shop staffed by PEs Thanks Alan. I'll tuck that one away for future reference.

Isn't it amazing what artistry can be accomplished on a low budget? Hell, intricate clocks were built centuries before CNC machines. Somehow little by little, artisanship is being "chipped away" (forgive the pun), yielding to economics, until it's suddenly a lost art; not worth pursuing because it doesn't pay enough and costs too much. Well I work in the Virtual Reality/CNC/Visualization labs at a leading appliance manufacturer whom has a hard-on for innovative design and sexy geometry. It's funny that what you did with styrofoam and sandpaper may have cost us thousands to produce. I love the spirit of innovation, especially when ingenuity is a player! You encourage guys like us.

Thanks,
Brian Jackson

[banaari]

Hi Alan,
That's a bloody nice piece of craftsmanship.

I'm about to start on my own pod, same method - the combination of stuff I want on the panel just won't fit in the standard commercial offerings. So... a couple of questions for you:

- Is the yellow colour in the gelcoat, or did you paint it?
- If you laid it up over a male mould, are/were there any issues with the smoothness of the finish on the exterior?
- I'm a complete fibreglass newbie - could you be persuaded to describe the entire process step-by-step?


thanks in advance,
John

[bhenders]

Alan: great job! Looking forward to hearing of your first flight in the Bee.