Installing a new panel and BDS window in N9410Y

I've been wanting a new style panel in my N35 Bonanza since I got it 5 years ago. Finally I located a panel from a later model bonanza, a V35A that had been in an accident. The panel was in good shape with all the switches and circuit breakers installed and I was able to pick it up at a reasonable price. At the same time I was able to get a BDS speed sloped windshield that hadn't been installed. When doing a panel mod its a _lot_ easier if the windshield is removed. As the photos will show access is much better with the window out.
A few have asked where I got the parts, Rainbow Salvage near Sacramento, CA. has a few wrecked bonanzas, and a hanger full of parts for bonanzas and other planes.

The images show the old panel and windshield.

This is the new panel at the bone yard.

1st Step: Removal of old parts. December 1997

The first thing we did was remove all the radios, then we took out the old 2 piece windshield, it came out pretty easy, but some of the newer ones are glued in, and can be hard to remove.

Here is Pierre, the A&P IA that I work with. We have now removed the window and are drilling out the rivets that hold the glare shield and panel in.

After the window, glare shield and trim panel are removed the instruments are readily accessible. Next step is to remove all the instruments and the floating panel.

The floating instrument panel and all the instruments have been removed.

Taking out the piano keys and radio trays.

What a mess! The piano keys and yoke mount are loose, but all the control cables must be removed to free them. Then the old wiring and insulation can be cleaned up.

2nd Step: Installing the center panel support. January 1998

The old center support with trim wheel, trim indicator, gear and flap indicators, ignition switch and engine controls was removed and the parts from the V35A where installed in their place. Even though the serial numbers of the planes where over 2000 apart most of the rivet holes lined up!

Along with the center panel support the control column had to be changed.

3rd Step: Installing the new panel. April 1998

The new panel is installed with clecos for a test fit. Some instruments where installed to check for clearance with the flight controls.

After riveting the panel it was painted with wrinkle finish black paint.

4th Step: Wiring and instrument installation. May 1998

The panel installed and painted, with a few instruments installed. The new prop, mixture and throttle cables where installed and the heater and fresh air cables hooked up. Wiring was hooked to the breakers on the panel.

The instruments where install with new hoses and checked for clearance with the flight controls. The avionics where tested for functionality as they where installed.

5th Step: Radios and stack installation. June 1998

The floating panel was installed with the flight instruments, all new static lines where used and the pitot static system was tested before the plane was returned to service. The radio stack was installed after all the radios trays where installed and tested.

The new panel with instruments and radios installed... At this time I'm thinking of taking off into the sunset... Its been 7 months now working on this project but its nearing completion... All thats left is the paperwork and window.

6st Step: Windshield installation. July 1998

First step in the window is the defroster.

Pierre prepping the new BDS window for installation.

Installing the window. The window is put in place and holes are drilled in it, the clecos hold it in place as the holes are drilled. Then its removed and the holes are drilled out to 1/4 inch for clearance. Each hole is countersunk to remove the sharp edges which could cause cracks later.

The window is in place and the fairing strip that holds the front of the window in place is installed. The strip is screwed to the window and riveted to the airframe.

The window is sealed in place with 2 part silicone... It dosnt take long to do, but the cleanup is a pain... It pays to be neat at this time... Here Pierre and Barbara ( who was taking time off from working on her Cherokee 235 to help the installation) are cleaning up the excess sealer.

Pierre with the installed window.

Another view of the window and panel -- compare this with the pictures at the top of the page.

7st Step: Paperwork and weighing the plane. August 1998

After all the parts are installed the plane is reweighted. Here the plane is getting ready to be pulled up on the scales, one for each wheel.

After the log entries and 337's are filed I'll be ready to ....

8st Step: Fly away! Sept. 7, 1998

The 1st flight was uneventfull, as all flights should be! :} I spent 15 minutes orbiting the Oakland Coluseum checking instruments, then landed and checked the engine and airframe. No problems where found!
It took 9 months to finish the project.... I had expected it to take 2-4 months.

Return to Joe's Bonanza page

Return to the Bonanza Page

As I get more work done I'll be adding to this page, so check in to see the latest progress.
Any questions, email me.
3/1/1999