Disassembly is now underway. The original fiberglass insulation's red dye had stained the headliner and some of it had deteriorated to the point of being dust. Removed all this in preparation for new sound deadening materials.

The carpet is scraped off the floor as well as the original foam insulation. Lots of cleaning and vacuuming here !

While the center floor board is up and the wall panels are out, I wire it for future expansion of the intercom for the rear passengers.

Now that everything is cleaned down, we put down a layer of Aerolite sound deadener. The object here is to line the entire cockpit and passenger areas with this high density material. Lots of cutting and fitting of each individual piece, but I believe it'll be worth it in the long run.

Before proceeding to the next step of sound deadening, I go ahead and mask the airplane off for repainting of the door jamb areas. This will provide us a smooth finished look when the new wind lace and upholstery are installed.

Next comes a layer of sealed fiberglass insulation. This will fill the voids between the panels, headliner, and the upholstered panels. Each piece has to be fitted to its bulkhead slot and sealed in a plastic bag. The bag will allow the insulation to stay pure and dry inside. 

Now that the door jambs are finished, new leather wind lace is fabricated and fitted to front, rear, and cargo doors. The headliner is sewn and fabricated and is installed at this same time.

The original wall panel boards are made out of some sort of cardboard type material. These have gotten wet and deteriorated over the years and are now down to nearly nothing. All the panels are severely warped .

The process of fabricating new wall panels is now underway.  I make these out of .020 2024-T3 aircraft sheet metal. This will insure we have a nice smooth look to the finished product and have wall boarding that will essentially last forever. Each panel has to be fitted to each wall position and each cabin and baggage door. The round-over pieces are carefully removed from the original wall panels and transferred to the new metal panels. These must be centered in their proper position under the windows. In this photo, you see an initial fit and check of the panels while the cut-outs are being made for seat belts, air vents, arm rests, etc. 

Each piece of plastic trim is removed, cleaned, and refinished with Jet-Flex aircraft interior finish. Plastic parts are replaced with new where necessary (several places).

I had a last minute design change here. Most of the plastic on the interior is to be finished in an off-white color. I felt this would be too much contrast against the leather, so I opted to go with a tan finish instead. The result was that the off white is on the plastic from the bottom of the windows up over the top. Anywhere the plastic is close to the leather and under the window areas (such as arm rests shown here) is done in the tan which closely matches the leather. The plastic vent trim on the floor will be black.

I also installed a new throttle quadrant plastic and decal kit. This basically comes as plastic parts you-make-a-throttle- quadrant-out-of-it.

Next comes the finish trim installation of the plastic. I bought new overhead air ducts since the original ones were broken and cracked. The reading lights are painted to match the rest  of the overhead plastic.

One of the big changes of this was to change the color of the panel from the greenish-brownish color to black. New decals where required and new leather eyebrow upholstery finish it out. The sun visors are replaced with new and pilot's side power setting chart is fabricated and installed on the new visor.

The nose baggage compartment is refurbished with carpeted side walls and additional sound deadeners on the firewall. The jambs are also refinished just like the cabin doors.