Replacing upholstered wall panels on Comanche 250

[Randy Johnson]

Would like any advice available in replacing the wall panels in my 1962 Comanche 250.

I have removed the old panels and found the factory wall board is basically sealed cardboard that is deteriorating on the edges. As with any project I have discoverd other issues ... decided to replace the airframe insulation behind the wall board as well. 50 years of annuals and repair work have taken their toll on the fragile fiberglass insulation...and some wiring that needs to be rerouted in the airframe.

Understand all new materials must meet FAA guidelines for flammability even though the material I am replacing would make great kindling to light the barbeque. Have ordered wall board (called poly board) and insulated wall foam from Airtex at their recommendation. The foam rubber is supposedly designed to insulate for heat/cold and for sound. It also is supposed to dampen airframe vibrations as it sticks to the airframe on one side. This is a standard step on a typical Airtex installation of new wall upholstrey.

There is excellent info on reupholstering the new board on the internet. Tricks of the upholstery trade is readily available. Obviously I am using the old panels as templates.

Although it all looks pretty straight forward ..and labor intensive, Im looking forward to the challenge. Any advice from lessons learned would be much appreciated. If anyone else is interested I'm happy to email pictures of the progress of the project.

[N3322G]

Randy,

I always l;like seeing other Comanche's naked fuselages. Photos of your project can be posted on this site as an attachment. I'm especially interested in the wiring etc

[Randy Johnson]

Happy to oblige. Here is port/aft panel removed by bench seat...more to follow

[Randy Johnson]

Here is aft/starboard wall with panel removed and bench seat removed

[Randy Johnson]

this is forward port wall panel with heater duct accessory removed

[Randy Johnson]

here are armrests removed and recovered. Original covers were real leather...wall panels were vinyl. Took about a half an hour each to re-cover. Not difficult with right tools and some patience. Used 3m 90 adhesive which worked great.

[N3322G]

Wow, nicely done. Thank you. I enjoyed the tour.

I don't have the patience or talent but sure do appreciate the results when someone else does.

FYI. You can add titles and post multiple photos per entry, just keep hitting attachment

[Randy Johnson]

More to come! Here is a wire bundle behind the left forward panel by rudder pedals

[Randy Johnson]

if anyone else is interested Iam happy to provide updates on my progress to re-upholster. Still would like to hear from the pros who have done this before!

[skipsouthernsky]

Dear Randy,

I intalled Airtex side panels in my 180 about 10 years ago. They fit pretty good and looked professional. I had the fabric to match seat kits that I installed also. I thought the interior ended up looking much better than I expected at the start of the project. Although all the materials are fabric, they are holding up fine. Not a top notch leather job of course, but certainly decent. The only quarrel I might have is that the floor carpet fades over a period of a few years. When comparing the carpet in the baggage to the carpet in the cockpit, there is a noticeable difference.

It still takes a lot of work to trim and fit the side panels and make attachments for them to be fixed in place. Making your own sounds like a pretty big job. IMHO I think letting Airtex do that fabrication work and paying them for their expertise is worth the money. There's still plenty to do after receiving the finished panels. Good luck with your knees. There's plenty of crouching to do during installation. You will understand better after you are done.

The finished job will make a positive difference in your (and your wife's and passengers) Comanche experience when flying.

Sincerely,
Skip Dykema

Ps: I don't see any wiring that looks like intercom with headphone and mike jacks. This is the perfect time to run the wires and mount the sterio jacks for a 4-place intercom. Later on you will wish you had done that. PS Engineering makes some real nice audio switching panels with built in intercom that really enhances your piloting experience. I know. I just put one in my other plane and it is huge step forward.

[N3322G]

Ditto on Skip's post for an intercom. We happened to use Garmin because we needed to do the whole audio panel at the same time. Works great. We especially like the split com when under class B space so one of us monitors local traffic and the other is on approach freq.

Thanks for the photos

[Randy Johnson]

Great advice. Thank you. Hadnt thought of the intercom. Just finished rehabbing the heater ducts...see pix attached

[N3322G]

Look really nice

[Randy Johnson]

Here is new insulation installation...also have ashtrays (for any one who would like them) wont be re-installing them.

[N3322G]

No use for the ashtrays either.

Almost took out the lighter but glad we didn't as it charges the iPAD2 in flight or phones.