Replacing upholstered wall panels on Comanche 250

[Zach Grant L1011jock]

Ash tray holes are a great place to mount the jacks for the intercom...
-Zach

[MULEFLY]

Replacing the ashtrays with a head set plug in for the rear seats is a great option... remove ashtray... fabricate aluminum plate... install and wire the two female plugs for the headsets... Mine look great!
Jim

Sorry just saw Zach's post suggesting the same thing...
jpc

[Randy Johnson]

I have completed the duplication of the wall panels.

Spent about a day on the heater ducts, a day on each of the five panels and a day for all four armrests. It took a day to remove the old panels and front and back seats, and a day to reinstall the new ones. I spent two days removing the old fiberglass insulation...cleaning the interior fuselage and replacing the fiberglass with special foam rubber coated with foil available through airtex. All told, I spent about 9 or 10 full days on the project. Could probably do it in half the time after doing it once.

I used airtex for the polyboard (wallboard) as well. Total cost from airtex for the polyboard and foam insulation was about $200 dollars. Add the cost of the vinyl, fiberfill, 3M 90 adhesive and assorted screws, spray paint, nuts and bolts, and tools totaling about $150..total cost of the project...about $350. The cost for completed panels from Airtex and the foam rubber was quoted at about $1400. So..if you value your time at more than about $100 a day take the shortcut and buy the finished product. I really enjoyed doing the work and doing it my way...learning volumes about my new airplane at the same time.

Many thanks to Dodd at airtex who answered every single question I had with patience. I challenged him more than once...He was always right.

Pictures wil follow. Had a great time doing the project...the silver lining of the recession...time to do things right!

[Randy Johnson]

Already have a four place intercom system although it clearly would be a good time to install it of you needed it. considered adding cigarette lighter to charge phone but its pretty tight behind the panels.

Here are pix of two of the panels that have been completely installed. The covering is a clay colored ostrich quill with buff white arm rests and heater ducts. Looks a little flashy now but when its all put back together it works. The seats for example cover at least half of the panels when installed.

The seats (next step!) will be a dark brown leather ostrich quill with dark brown cloth inserts. The seats will match the dark brown carpet (airtex) and dark brown plastic and aluminum components like heater duct ends, blower and window sill components.

[9089P]

Hi Randy,

I could be mistaken but I think the one arm rest (of the 4 you have) that is also a "handle" should be on the door, not on the pilot's side wall. That way you can use it as a handle and avoid pulling on the chrome lever that serves to latch the door.

Good luck, Don

[Randy Johnson]

Thanks Don. That makes alot of sense. Mine were switched even though the wall board upholstery is original! Learn something new every day.

Finished removing old fiberglass insulatiom, cleaning, and imstalling new aviation foam insulation underneath the floorboards. Took an entire day. The wall insulation also took a day. Was careful to keep weep holes open and to not cover rivet lines for future inspection.

I was really surprised at how the fiberglass had turned to dust in many places. Guess 50 years takes its toll on everything. Also found a small cable bundle that was close to being pinched by the flap pulley and wire cable.

Question...anyone use rubber table or another product in between sheet metal floorboards and ribs where screws are attached? The purpose would be to provide a tight fit and less rattle.

Also is graphite a useful lubricant for the wires and pulleys?

[MULEFLY]

I would be hesitant to use a rubber table between the floors and the ribs for the same reason that it has been stated that the carpet should be cut around the seat rails. I might be wrong, but you want those screws as tight as possible into the nut plates so that no "rocking" (even minor amount) can happen. A number of years ago when I was looking to purchase my first Comanche... I found a pretty good airplane up in Canada... except the floor was out of it and 3 stringers were being replaced due to excessive rocking of the seat rails had damaged them.

Just my 2 cents.

I have no opinion on the graphite other than I try and only use Piper recommended lubricants or equivalents. That goes so far as to use the Duke's grease in the gear transmission ... it is 10% moly and the only place that you can get it is Dukes.

Jim

[Randy Johnson]

Thanks for the advice. I appreciate it.

Here is my completed project. Wall boards are newly built using old wallboards as templates. Pictures show final wallboard installation back bench and seats removed . Total cost $350..total labor about ten days. Project also included removing the floor board and bulkhead insulation...cleaning and placing aviation foam as insulation. Wallboard and foam purchased from Airtex.

[Randy Johnson]

Rear seat reupholstered and installed

[Randy Johnson]

Finished product...front seats installed...one at a time. Total cost of project about $1200. Had the seats finished by a pro. I reproduced wallboards with aviation polyboard and removed and replaced all cockpit insulation with aviation foam. Cleaned 50 years worth of grease, dust and varmit residue as I progressed in project with DAP cleaner. Also removed and repainted luggage compartment floor and walls replacing fasteners with stainless ones. Took me about 30 hours. Could do it again in half the time as I had not done this type of work before.

[skipsouthernsky]

Dear Randy,

Nice looking job. You should be proud of it. I'm sure you saved a few thousand dollars.

Sincerely,
Skip Dykema

[N3322G]

Way to go - bet you smile every time you open that door.

[David Pyle]

30 "Brownie" points. Good for you.