Updating an Older Airplane

A forty year old Cessna 172

gets a facelift and a new heart
April, 2005

Stan Cooper

A Metamorphosis
from This

to This

N2686U A 63 Cessna 172D

2200 Hours Airframe Total Time

220 Hours SMOH Continental O-300-C
Original Shotgun Panel
Avionics Stack Limited to Height (T Control
Column)
Optional 35 Amp DC Generator Electrical
System
Circuit Protection: AGS Fuses
Dual Narco Mark 16 360 Channel NavComs
30 Years at SNA (Orange County) Lots of
Surface Corrosion
Two previous owners (17 years) were A&P
mechanics and CFIs who taught their wives and
children to fly in the airplane
3

Why A 1963 Model?

63 was the first year the 172 had the OmniVision rear window looks similar to the new
2003 172S
Higher gross weight (2,300 lbs vs. 2,250 lbs) with
same empty weight, resulting in higher useful
load than earlier years
The 63 still had manual flaps simpler, faster to
deploy and retract, and arguably more reliable
than electric flaps
Continental O-300 six cylinder engine (some will
debate whether this is an asset or a liability)
At $26,500 I could afford it
4

The Project Scope

Replace the instrument panel with a new STCd one from Avion
Research conforming to FAR 23.1321, including new AI and DG
Update the electrical system from DC generator to 50 amp STCd
Skytronics alternator; replace fuses with circuit breakers
New avionics stack PS Engineering 6000 Audio Panel/Intercom
King KLX 135A GPS/Com
King KY97A Comm
Narco NAV 121 VOR Receiver
Monroy ATD300 Traffic Detector
Garmin GTX 320A Solid State Transponder
S-TEC 30 Autopilot
King KMD 150 MFD/GPS
New electronic tach, volt/ammeter, and chronometer
Strip old paint, remove corrosion, prime and paint
New interior, including B.A.S. shoulder harnesses
Six new ECi TITAN cylinders with Real Gaskets pushrod tubes
5

A Few Words to the Wise

Before beginning major work on any certificated
airplane, discuss the project with your A&P/IA
and your local FSDO inspector.
Tell them exactly what you want to do and how
you plan to do it.
Find out what paperwork will be required and
agree on whos going to do what.
After youve described what youre going to do,
dont make any changes.
Keep the FSDO inspector informed of your
progress and invite him/her to stop by any time
to inspect the work.
6

The Mid-eighties Paint Job

.. It probably looked great at the time.

7

The 1963 Vintage Shotgun Panel

63 was the last year the 172 used a T control column.

8

The U Column Permits a Full Height

Center Avionics Stack
The 63
T Control Column

and the 64
U Control
Column

Hmmm.. Do I Really Want To Do This??

Original Defroster Nozzle

Original T Control Column

(Interferes with new gyro

instrument vacuum fittings
and hoses)

(Limits avionics stack to

half height)

10

Getting There..
New Defroster Nozzle

New U Control Column

(Prevents interference
with AI and DG vacuum
fittings and hoses)

(Permits full height

Avionics stack)

11

Testing the avionics and

Pre-wiring the panel

Avionics and harness bench tested before installation

All panel instrument and avionics grounds terminate
on a copper buss connected directly to negative
battery pole (fuselage not used for ground return too
much noise)
12

The New Electrical Wiring Diagram

FUEL GAUGES

FAA Form 337, Block 8

ALTERNATOR
OUTPUT A
(WHITE)
REG
(AUX)
(RED)

FIREWALL

JASCO
J12M20SP
12V
CONTROLLER

CABIN
LIGHT S

AVIONICS
FAN

AMMETER

INSTR
LIGHT S

WH/
RED

BLK

BLK

REG

YEL

20 AWG

18 AWG

MASTER
A
L
T

B
A
T

P
R
I
M
A
R
Y
B
U
S

U.S.A. N2686U Date July 13, 2004

NAV
LIGHT S

NAV
LIGHT S

ST ROBE
BCN

10

ORG

20

18 AWG FA1

18 AWG
TACHOMET ER

10
TACH

WHITE

STARTER

V IN

.1 F
LM 150K
5K

CASE IS OUTPUT

240
1

2 - 11 VDC
OUTPUT

INSTRUMENT LIGHTS DIMMER

MODULE

D.C. POWER WIRING - CESSNA 172D N2686U

S/N 17250286
S. COOPER REV. 7/13/2004

TAXI (OUTBOARD)

AVIONICS
MASTER
RADIO 1

A
V
I
O
N
I
C
S

RADIO 2
10

RADIO 3

B
U
S

7
RADIO 4
5

CESSNA DWG 0500062

PAGE 11.3 REV D 9-10-62

14 AWG LE1

WARNING
HORN

CESSNA DWG 0500062

PAGE 9.1 REV D 9-10-62

18 AWG FA2

ST ALL SWIT CH
LEF T WING LEADING EDGE

18 AWG FC3
AP/TURN COORD PIN 14
AP/PITCH COMP PIN 1
CIGAR LIGHTER RECEPT ACLE

P-1000
BLK

CESSNA DWG 0500062

PAGE 11.4 REV D 9-10-62

LANDING (INBOARD)

TURN & BANK

18 AWG

CESSNA DWG 0500062

PAGE 11.2 REV D 9-11-62

CESSNA DWG 0500062

PAGE 11.5 REV D 9-11-62

14 AWG LC2

OFF

AUX POWER
18 AWG

ADJUST MENT

FLASHER
ASS'Y

LANDING
TAXI LANDING

LANDING
TAXI

13.8 VDC

FLASHING BEACON
LAMP

ST ROBE (NC)
OFF
16 AWG LF2
BCN

18 AWG FC2
3
S-T EC 30 AUTOPILOT

STARTER
"T" HANDLE

TAIL

18 AWG LD11
ST ROBE
BCN

18 AWG LB4

P1A, KLX135A
P97A1, PIN B, KY97A
P101, PIN 4, AT 50A
P810, PIN 27, NAV121

ST ARBOARD

18 AWG LD4

ST ALL WARN
BRN

18 AWG LB3

22 AWG
22 AWG
22 AWG
22 AWG

COMPASS
LIGHT

18 AWG LD2

10

AMMET ER
SHUNT

CLOCK
LIGHT

INSTR
LIGHT

PORT

TURN COORD

DIMMER
MODULE

18 AWG LB2

INSTR & COMPASS

LIGHTS

TAXI

AL T
FIELD

S50

CESSNA DWG 0500062 PAGE 11.1 REV D 9-1162

RADIO LIGHTS

DIMMER
MODULE

18 AWG LB1

10

VA1A-50

18 AWG

4 AWG

CESSNA DWG 0500062 PAGE 8.1

REV D 9-11-62

18 AWG LA1

WH/BRN

6 AWG

EB2
MAP LIGHT

INSTR
LIGHT S

18 AWG

BATTERY CONTACTOR

DOME LIGHT

TROLL
FN-200

2A FUSE
1A
FUSE

GRN

EB4

18 AWG LA7
50

RED

ALT FIELD C
(GRN)
GROUND
(BLK)

CABIN
LIGHT S

AL T

RED
ORG

18 AWG

FUEL GAUGE T RANSMITT ERS

R
EB5

10

8 AWG SHIELDED

18 AWG EB1

CESSNA DWG 0500062

PAGE 15.1 REV D 9-10-62
CESSNA DWG 0500062
PAGE 13.1 REV D 9-11-62

L.H. MAG
L
R
IGNITION SWITCH

R.H. MAG

CESSNA DWG 0500062

PAGE 5.1 REV D 9-11-62

18 AWG

PIN 20, J1, PMA 6000 AUDIO PANEL - PS ENGINEERING DOCUMENT 200-066-0002 REV. 2, MAY 1999

20 AWG

PIN 7, P810, NAV121 VOR RCVR - NARCO NAV121 MAINTENANCE MANUAL 03723-0600, 9/79, T ABLE 2.2A & FIG. 2-9

20 AWG

PIN 26, P810, NAV121 VOR RCVR - NARCO NAV121 MAINTENANCE MANUAL 03723-0600, 9/79, T ABLE 2.2A & FIG. 2-9

18 AWG

PIN 6, P4001, KLX135A GPS/COMM - ALLIED SIGNAL INSTALLATION MANUAL 006-10500-0003, REV. 3, AUG 1995, FIG. 2-1, SHEET 3 OF 5

18 AWG

PIN 7, P4001, KLX135A GPS/COMM - ALLIED SIGNAL INSTALLATION MANUAL 006-10500-0003, REV. 3, AUG 1995, FIG. 2-1, SHEET 3 OF 5

18 AWG

PIN 8, P4001, KLX135A GPS/COMM - ALLIED SIGNAL INSTALLATION MANUAL 006-10500-0003, REV. 3, AUG 1995, FIG. 2-1, SHEET 3 OF 5

18 AWG

PIN R, P97A1, KY97A COMM - ALLIED SIGNAL INSTALLLAT ION MANUAL 006-00674-0003, REV. 3, APR 1994, FIG. 2-8

18 AWG

PIN 14, P97A1, KY97A COMM - ALLIED SIGNAL INSTALLATION MANUAL 006-00674-0003, REV. 3, APR 1994, FIG. 2-8

18 AWG

PIN 16, P101, AT 50A TRANSPONDER - NARCO AT 50A MAINT ENANCE MANUAL 03604-602, SEPT 1972, FIG. 2-1

22 AWG

CENTER PIN, POWER JACK, ATD-300 - MONROY ATD-300 OWNERS MANUAL MA-300, REV 1.6, 1-2004, F IG. 6

18 AWG

PIN 37, 37 PIN CONN, KMD 150 MFD/GPS - ALLIED SIGNAL INSTALLATION MANUAL 006-10607-0000, REV. 0, NOV 1999, FIG. 2-10

13

Fitting the New Panel and Avionics

14

Avionics Interconnection Diagram

PMA6000
TOP (J2)

FAA Form 337, Block 8, Item 3

3
C
1
A
5
E
6
F
9
10
K

CO-PILOT PHONES HI
CO-PILOT PHONES LO
PASS PHONES HI
PASS PHONES LO
PASS 1 MIC HI
PASS 1 MIC LO
PASS 2 MIC HI
PASS 2 MIC LO
CO-PILOT MIC AUDIO
CO-PILOT MIC PTT
CO-PILOT MIC LO

4
D
N
12

PASS 1 PHONES
PASS 2 PHONES

KLX135A
P4001

KMD150
P1

13
14
3
P
N

37
25
13
12
30

12 VDC POWER - RADIO 4 CKT BRKR

GROUND
DG
52D54
SIG REF
EXC REF
AC HDG

CO-PILOT MIC

6
7
8
F
J

CO-PILOT PTT IN
CONTROL WHEEL
EXTERNAL ENTERTAINMENT

12 VDC POWER - "RADIO 2" CKT BRKR

S-TEC 30
P1
2
J
K
15

BOTTOM (J1)
9
P
R
19
L
10

U.S.A. N2686U Date July 13, 2004

H
V
16
M
T

KLX135A AUDIO HI
KLX135A AUDIO LO
KLX135A MIC AUDIO HI
KLX135A MIC KEY
KLX135A SPKR LOAD

KY97A AUDIO HI
KY97A AUDIO LO
KY97A MIC AUDIO HI
KY97A MIC KEY
KY97A SPKR LOAD

H
7
J
9
E
5
R
14
F
6
S
15

TRAFFIC ANNUNCIATOR

12

NAV121 AUDIO HI

20

12 VDC POWER - "RADIO 1" CKT BRKR

3
22
W

PILOT PHONES HI
PILOT PHONES LO
SPKR HI
SPKR LO
PILOT MIC AUDIO
PILOT MIC PTT
PILOT MIC LO

1
Z

DATABASE IN
TO RS232 JACK
DATABASE OUT
ON PANEL
GROUND
(GPS DATA LOADER)

KY97A
J97A1

NAV121
J810

8
Y

E
B
D
A

36
7
26
19

+ RT
+ LT
GPS GAIN
JMPR
CUT FOR
DG

6
5
3
35
10
9
19
42
20
21

12 VDC POWER
"RADIO 3" CKT BRKR

12 VDC POWER - "RADIO 1" CKT BRKR

ATD-300
600 OHM AUDIO
(RING OF "PHONE-SPEAKER" JACK)

MOUNTING
STUD
CABIN SPEAKER

PILOT PTT IN
CONTROL WHEEL

12 VDC POWER - "RADIO 4" CKT BRKR

AVIONICS INTERCONNECT WIRING - CESSNA 172D N2686U

S/N 17250286
S. COOPER REV. 5/28/2004

AIRFRAME GROUND

15

S-TEC 30 Autopilot Installation

Panel Showing Turn Coordinator/Roll Computer and DG with Heading Bug

Pitch Computer

Pitch Servo

Pressure Transducer

Roll Servo
16

Solid State Dimmers Replace Rheostat

- Instruments
- Radios
Same circuit
as in new 172R,
except set up
for 12 V system
instead of 24 V
system
Safer and more
efficient than
rheostats
17

Electrical System Load Budget

Item
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Maximum Current Load

PMA 6000 Audio Panel

KLX 135A GPS/Comm
KY97A Communications Transceiver
GTX 320A Transponder
ACK A30 Encoder
NAV 121 VOR Receiver
KMD 150 MFD/GPS
S-TEC 30 Autopilot
ATD-300 Traffic Detector
P-1000 Tachometer
VA-1A-50 Volt/Ammeter
Dome Light (GE 1816 Bulb)
Map Light (GE 58 Bulb)
Fuel Quantity Indicators
Instrument Lights (GE 94 Bulb)
Compass Light
Landing Lights (Taxi and Landing)
Strobe
Navigation Lights
Stall Warning Horn
S-TEC Turn Coordinator
TOTAL MAXIMUM LOAD

1.00
Ampere
6.30
Amperes (Tx)*
1.10
Amperes (Rx)
2.00
Amperes
0.30
Ampere
0.87
Ampere
1.50
Amperes
5.00
Amperes
0.20
Ampere
0.20
Ampere
0.10
Ampere
0.33
Ampere
0.58
Ampere
0.36
Ampere
1.10
Amperes
0.08
Ampere
15.60
Amperes
1.70
Amperes
5.60
Amperes
0.25
Ampere
0.30
Ampere
===============
44.47
Amperes

* KLX 135A draws 6.3 amperes in Transmit, KY97A draws 6.0 amperes transmit. Since
only one comm unit transmits at a time, the table shows worst case. Transmit load
is transitory, not continuous.

18

Weight & Balance

19

Weight & Balance (Contd)

20

Finally!!!

21

Millennium Falcon??

Exterior stripped, surface corrosion removed,

Alodined, and prepped for primer

22

Primed and ready for paint..

23

Photo from 63 Factory Brochure

24

And the New Paint on N2686U

The strip and paint was done by T&P Aero Refinishers

in Salinas, CA. I think they did a fantastic job..
25

Interior Before

26

Interior and After

Kit by Hangar Bay Aircraft Interiors

27

New ECi Cylinders

1. Original Continental Cylinders

5. All back together with powdercoated

baffling, new Lord engine mounts

2. Baffling, exhaust system,

intake system, old cylinders
removed

3. Cam and lifters in

good shape

4. New ECi cylinders with Real Gaskets

STCd pushrod tubes installed

28

Costs (Labor Not Included)

N2686U . . . . . . . . . . . . . .
Avion Panel and Control Wheels . . . . . .
New RC Allen AI . . . . . . . . . . .
New Sigma Tek 4000C DG with Heading Bug . . .
King KLX-135A GPS/Comm
. . . . . . . .
King KY-97A Comm
. . . . . . . . . .
Garmin GTX 320A Transponder . . . . . . .
PS Eng PMA6000 Audio Panel/Intercom . . . .
Narco NAV121 VOR Rcvr . . . . . . . . .
King KMD 150 MFD/GPS . . . . . . . . .
S-TEC 30 Autopilot . . . . . . . . . .
Skytronics/Jasco Alternator . . . . . . .
Monroy ATD-300 Traffic Detector
. . . . .
Horizon Tach, EI Volt/Ammeter, Clock . . . .
Miscellaneous (wire, breakers, hoses). . . .
Strip and Paint (includes labor) . . . . .
New Interior and B.A.S. Harnesses . . . . .
Six ECi TITAN cylinders and STCd pushrod tubes
TOTAL

. $26,500
.
3,395
. . 425
.
1,191
.
2,095
. . 989
.
1,230
. . 904
.
1,149
.
2,875
.
7,845
. . 724
. . 595
. . 861
. . 500
. 13,000
.
2,500
.
5,000
=======
$71,778
29

LETS GO FLYING!

30