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Attaching backlit panels to the center and TQ pedestal

Hi guys,

Continuing on with mounting panels in your build, I have written this tutorial to give you some ideas on mounting your panels in the center pedestal and throttle quadrant pedestal.  One of our active builders, Maciej, who is building a full shell sim noted this method in his build thread and I am adding some information for new builders in this tutorial in case they might have missed the information in Maciej’s build.

If you are starting to build the Lear 45 and you are using the interior pieces from Project45 or using the plans from Project45 or building your own center and TQ pedestal out of wood you may be interested in this tutorial as it will provide you with a mounting method that will last thru years of installing and removing panels.

One method is simply mounting your panels using the 6-32 screws directly into the wood but this method sometimes fails as the threads in the wood can fail.  Installing threaded metal inserts on the other hand will offer a better installation method.

I am using 6-32 threaded brass inserts specifically made to add metal threads to furniture.  I have posted links to the threaded inserts I am using and the tool used to mount them below. I opted to use the tool as it helps getting the insert started correctly in the wood but you could use a straight screw driver.

Link to brass inserts.

Shane 54

 

Link to installation tool.

Shane 55

 

Tools you will need to install the inserts include:

A ¼ inch drill bit.

Drill stop / not necessary but handy to drill the same depth hole each time.

Drill.

Straight blade screwdriver.

Shane 56

 

One recommendation is to get your panels laid out with all switches and hardware attached as you want them on your center pedestal and TQ pedestal to ensure they will fit correctly.  You may find some of your switches or hardware may interfere with the placement of other panels. Do this before mounting your TQ and center pedestal in your shell.  It’s much easier to work on them outside of the shell where you have plenty of room.  If you have not already painted your pedestals, I would suggest doing this prior to painting.  If you make a mistake it’s easier to fix and hide the mistake before painting!  

 

So what we are wanting to do is go from this:

Shane 57

 

To this . . . and you can see why I suggest doing this before painting!

Shane 58

 

Once you have your panels laid out on the pedestals where you want them go ahead and carefully drill small 9/64 inch pilot holes at each panel attachment point.  Make sure your panels don’t move around on you as this will cause you problems with alignment of the panels later.

Once you have all the pilot holes drilled for all panels you can start drilling the ¼ inch holes to mount the brass inserts.  Drill the ¼ inch holes to a depth that will allow the brass insert to be flush with the top of your pedestal.  Using the tool or straight blade screwdriver carefully start threading the insert into the hole ensuring you are keeping the threaded insert straight and it is not going in at an angle:

Shane 59

 

I would suggest drilling the ¼ inch holes for one panel, mounting the brass inserts, then mount the panel to make sure you have everything lined up correctly then move on to the next panel. If you make a mistake with the hole alignment use a product such as liquid metal, fill the hole and try again . . . mistakes happen.

Once you have your threaded inserts in place you may encounter a few panels that do not want to line up or fit exactly right.  One way to fix small alignment issues is to enlarge the mounting holes on the panels.  The panel mounting holes usually are around 9/64 inch size holes.  Enlarge these holes to 11/64 inch and this help with small alignment issues.

I hope this tutorial gives you some ideas on mounting the backlit panels on the wood pedestals.  If you have any questions on mounting the panels to the center pedestals feel free to ask in this forum tutorial.  Have fun with your build guys and remember to share updates with us!