12/26/2006
After mulling it over for weeks I decided to install the pilot headset jacks in the instrument panel in the space under the radio stack. It is the least undesirable of many other undesirable locations. Mounting the jacks on the far right or left would result in the headset wires dangling over the switch panel or throttle/mixture controls. All other locations seemed run a risk of being constantly bumped into by knees and elbows.
I fabricated a plate to go in front of the space under the radio stack. I made it of .063, primed and painted it flat black. I mounted it to the panel with angles and spacers on each side. I drilled holes for the headset jacks.
Running the shielded cable for the phones took well over two hours because I messed up. I used 3 conductor wire rather than 2 since I might need to use the third conductor for the mic key line. I don't know why this would need to be shielded but this is what the audio panel schematic shows. Well, I managed to screw this up where the same two wires were not hooked up on both ends. To compound this I had already poped in the edge connector terminals when I figured this out. I had to fabricate a tool for removing the terminals.
I re-fabricated the two cables and this time they were right. I installed them and tested the intercom, radios, etc. Everything works.
I crawled under the instrument panel again to tidy things up. I tie wrapped everything in sight. I can't think of anything else that needs to be done besides wiring the engine sensors so I think I will declare this phase of the project done for now.