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 Post subject: Interior Panels: new Widgeon interior
PostPosted: 25 Oct 2018, 22:03 
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Joined: 05/05/09
Posts: 4946
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Aircraft: G44, C501, C55, R66
I'm in the process of redoing my Widgeon interior. I'm basically starting over from scratch. I ended up using 6 mil plastic to make templates of the ceiling, sides and carpet. I've transferred the plastic to cardboard to formalize the fit and then to .060 Kydex aircraft plastic as the backing material. A few questions to anyone that has done this before.

1) Should the panels have any relief around them for the thickness of the leather? My gut feeling is yes, this dimension matters.

2) I'm trying to figure out a way to avoid have any visible screws showing. Velcro? My interior guy says velcro glued on with car vinyl top cement doesn't creep. These panels are light enough and have enough additional support that I think the velcro will be OK. I have some aluminum H and J channels that I think I'll incorporate also to hide the seams and provide support.

Seats turned out amazing with the hotrod shop; as good or better than the finest interiors I've done in airplanes. I plan to deliver them the panels and get them covered with leather for the sides and Ostrich ultraleather for the headliner.

$7K for mostly rolling my own versus $40K for dropping it off at the airplane shop. On the other hand, these guys earn their money. It's 100s of hours of labor to do this properly; not including the actual sewing.


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 Post subject: Re: Interior Panels: new Widgeon interior
PostPosted: 26 Oct 2018, 19:30 
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Aircraft: G44, C501, C55, R66
Doesn't look like much but I cut most of the kydex today and thermoformed the curved piece. I highly recommend this material over the 20 thousands aluminum for side panels. Probably using SRS for the carpets


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 Post subject: Re: Interior Panels: new Widgeon interior
PostPosted: 26 Oct 2018, 19:34 
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Joined: 05/05/09
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Aircraft: G44, C501, C55, R66
One piece windshield mod and panel blank


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 Post subject: Re: Interior Panels: new Widgeon interior
PostPosted: 27 Oct 2018, 15:37 
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Joined: 07/02/13
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Location: Stamping Ground, Ky
Aircraft: twin bonanza
How does Kydex hold up? I’ve seen a couple of airplanes with what I think was kydex get warped pretty good sitting on a hot ramp. Not sure if that was just a not great install, or something that could be a problem.

Love the Widgeon. Nice work. Widgeons are high on my dream list. :cheers:


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 Post subject: Re: Interior Panels: new Widgeon interior
PostPosted: 27 Oct 2018, 22:48 
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Joined: 05/05/09
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Aircraft: G44, C501, C55, R66
Username Protected wrote:
How does Kydex hold up? I’ve seen a couple of airplanes with what I think was kydex get warped pretty good sitting on a hot ramp. Not sure if that was just a not great install, or something that could be a problem.

Love the Widgeon. Nice work. Widgeons are high on my dream list. :cheers:


Kydex is the same stuff they use on airliner sidewalls. It's the same stuff citation and Eclipse plastic around the windows is molded out of. It definitely distorts and warps with heavy heat but I think covered in foam and leather, it's going to be perfect. I probably would use it for window moldings as a manufacturer though.


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 Post subject: Re: Interior Panels: new Widgeon interior
PostPosted: 29 Oct 2018, 22:11 
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Joined: 04/06/17
Posts: 50
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Aircraft: be35,G44A,PA22-20,
I found my Widgeon had a mix of aluminum-backed and thin plywood-backed interior panels covered with very old vinyl. Left a few of the smaller wood-backed panels out when I put interior back in, because they crumbled like dry leaves when I moved them..Your engine cowl metal work done?


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 Post subject: Re: Interior Panels: new Widgeon interior
PostPosted: 30 Oct 2018, 09:09 
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Joined: 05/05/09
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Aircraft: G44, C501, C55, R66
Username Protected wrote:
I found my Widgeon had a mix of aluminum-backed and thin plywood-backed interior panels covered with very old vinyl. Left a few of the smaller wood-backed panels out when I put interior back in, because they crumbled like dry leaves when I moved them..Your engine cowl metal work done?


Mine was the same. The front side panels were crumbled/rotted plywood, the back was aluminum down low and vinyl directly over the metal frame up high. Total mess! next step is to mock install the Kydex panels before sending them off to get covered.

Right metal cowling is probably 85% done and the left is 60%. The instrument panel is about ready to be sent out for the installation of some shiny Garmin goodies.

Shy of reskinning the entire airplane, this will be about as close to a new Widgeon as possible. Given the size of this thing, it was probably more like rebuilding a King Air than a Baron. Way more work than I thought. I would have paid top dollar for an already done one if I had known this was going to be a 2000+ hour multi-year project.


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