SAC Aero Design FAQ: Custom Avionics Panels, Wiring, CAD, Pricing, and FAA Regulations

SAC Aero Design is a veteran-owned avionics fabrication shop specializing in custom instrument panels for experimental and amateur-built aircraft. Our team includes two retired U.S. Air Force avionics technicians and a software engineer. We design panels in Autodesk Fusion, CNC-cut them to precise tolerances, and build aircraft-grade wiring harnesses tailored to your avionics suite.

We build custom avionics panels exclusively for experimental/amateur-built (E-AB) and experimental light sport (E-LSA) aircraft. This includes popular kits such as:

• Vans RV series (RV-7, RV-10, RV-12, etc.)
• Zenith CH-650 / 750 / 701
• Kitfox
• Sling
• Sonex
• RANS

We do not build panels for certified (Part 23) aircraft. Our work is focused entirely on experimental and amateur-built aircraft

Our work is intended for experimental aircraft, where the builder/owner acts as the "manufacturer" and has broad authority to install avionics and electrical systems under FAA Order 8130.2 and the Amateur-Built exemption. At this time our team is not FAA certified, and we are not working on certified aircraft. However, our team still brings decades of real-world military avionics experience to every build.

We always recommend consulting your local FSDO or EAA Technical Counselor to ensure your installation meets all applicable requirements.

Absolutely, we offer free consultations. We are happy to discuss your aircraft, avionics goals, budget, and timeline before you spend a dime. Reach out via our contact form to schedule a phone or video consultation.

We do our best work for builders who:

• Want a clean, professional panel, not just a functional one
• Value thorough documentation and support designed to help you make the most of your delivered panel
• Are planning ahead and have time to collaborate on the design
• Want a single point of contact from first concept to finished product

We are not the best fit for:

• Certified (Part 23) aircraft owners. We only serve experimental/E-AB
• Ultra-budget builds where cutting corners is a requirement
• Last-minute or rush installs with no planning runway

Not sure? Send us a message. A 10-minute conversation will tell you everything you need to know.

The more you can share upfront, the faster and more accurate your quote will be. Ideally, have the following ready:

• Aircraft model: make, kit series, and any relevant airframe details
• Build stage: are you in early planning, mid-build, or retrofitting an existing aircraft?
• Avionics list (or rough idea): specific models if you know them, or your goals if you don't
• Budget range: even a rough number helps us scope the project honestly
• Timeline: when do you need the panel, and how flexible is that date?
• Panel dimensions or template: if you have them; we can help you measure if not

Don't worry if you don't have everything. We will walk you through the gaps during your free consultation. Start the conversation here.

Yes, phased builds are very common among experimental builders, and we're set up to support them well. Here's how a staged approach typically works:

• Design now, build later: Lock in your CAD design and get the files. Fabricate when your budget and timeline are ready
• Panel now, wiring later: Get a bare CNC-cut panel installed in your airframe, then add the harness when your avionics arrive
• Partial harnesses: Build out your primary bus and avionics first, add secondary systems later
• Upgrade path: Start with VFR, design with future IFR or glass cockpit expansion in mind from day one

Planning a phased build? Tell us early. We can design your panel to accommodate future upgrades without rework.

Absolutely. Retrofits and upgrades are a significant part of what we do. Whether you're adding a glass panel to an existing VFR setup, replacing aging gauges, upgrading to ADS-B, or starting fresh with a completely new layout. We can take it on.

Send us photos of your current panel, your aircraft type, and what you'd like to change. We'll assess the scope and put together a plan.

Our process includes five stages:

1. Consultation: We review your aircraft, avionics wishlist, mission, and budget.
2. Design: We create a full CAD model in Autodesk Fusion and provide renders for review.
3. Fabrication: Your panel is CNC-cut, finished, painted, and engraved.
4. Integration: Avionics are installed, wired, and fully bench-tested.
5. Delivery: We ship your completed panel with proper documentation.

Typical lead times after initial consultation:

• CAD/ Design Services 1-2 weeks
• Bare CNC-Cut Panel: 2-4 weeks
• Complete Panel builds: 8-12 weeks

Times may vary based on factors like avionics availability, revision cycles, customer delays, current workload. We will provide a realistic timeline before you commit. Rush options may be available.

Included revisions vary by package:

• CAD/Design Services: 2 revisions
• Bare CNC-Cut Panel: 4 revisions
• Complete Panel: 6 revisions

Additional revisions are billed hourly, though most customers finalize their design within the included revisions.

Accurate dimensions are essential. We maintain reference data for many common aircraft kits and can assist with measuring non-standard or custom installations as needed. Photos, measurements, and any existing templates help ensure precision. All dimensions are verified before cutting.

Once you sign off on the final CAD design, here's what the process looks like:

1. Deposit: A 50% deposit is collected to reserve your build slot and begin material procurement
2. Fabrication queue: Your build enters our queue. we'll give you an estimated start date and target completion window
3. Build updates: We send photos and progress updates at key milestones, after cutting, after finishing, and during wiring
4. Final approval: Before shipping, we send a full photo set of the completed panel for your review
5. Shipping: Balance collected, panel packaged, shipped with tracking and insurance, with all documentation included

You're never in the dark during your build. If you have questions at any stage, just reach out.

Every completed panel ships with a documentation package designed to make installation and future maintenance straightforward. Included documentation typically covers:

• Wiring diagrams: Full schematic of your harness with wire gauge, color, and routing
• Pinouts: Connector-by-connector pin assignments for every avionics unit
• Labeling scheme: Reference list for all wire labels and bundle IDs
• Install notes: Step-by-step guidance for mounting and connecting your panel
• Troubleshooting guidance: Common issues and how to diagnose them

This documentation is also what your EAA Technical Counselor or DAR will want to see during inspection.

We provide basic post-delivery support to assist with installation and initial setup. This includes reference to your project documentation and general guidance to help you complete installation and troubleshoot common issues. More advanced or hands-on support is not included unless specified in your project scope.

After working with dozens of builds, these are the mistakes we see most often:

• Not planning for future upgrades: Designing a panel with no room to grow means costly rework later. Always build in expansion space
• Underestimating wiring complexity: A panel with 8+ avionics units and a full bus isn't a weekend project. Experienced harness work matters
• Cutting corners on documentation: Undocumented wiring is a safety risk and makes future maintenance or resale far more difficult
• Picking avionics without a layout plan: Buying units before confirming they physically fit together in your airframe causes expensive problems
• Starting too late: Custom panels take time. Beginning the design process well before you need the panel avoids timeline pressure

We catch most of these before they become problems. A free consultation early in your planning is the best way to avoid all of them. Schedule one here.

We primarily use 6061-T6 aluminum, the industry standard for aircraft panels. Typical thicknesses are 0.063" or 0.090" depending on size and stiffness requirements. We can also work with 5052 aluminum or composite materials upon request. We do not recommend steel or raw plastics for primary panel structures.

Available finishes include:

• Bare aluminum: Deburred and ready for your own finish
• Flat/matte black automotive grade paint: Low glare, professional appearance
• Anodize (clear or black): Hard, durable surface
• Custom color automotive grade paint: Most RAL/Pantone colors available

Yes, LED panel lighting is a popular upgrade. We design lighting-ready cutouts and provide a complete LED kit with adjustable dimmer. Available colors include red (night-vision friendly), white, blue, green etc. The dimmer can be panel-mounted or remote-mounted.

Absolutely. Laser engraving is included for all switch and instrument labels. Custom text, logos, callsigns, N-numbers, and unit markings can be added for a small additional fee. We use a high-resolution laser engraver for crisp, permanent results.

We design and fabricate panels around any avionics you choose. We work with all major experimental avionics manufacturers including Garmin, Dynon, AFS, GRT, Avidyne, and others — if it's approved for experimental aircraft, we can build around it.

Not sure which avionics suite to choose? We're happy to walk you through the options during your free consultation. Reach out and let's talk.

We are currently establishing dealer partnerships with major avionics manufacturers. Once finalized, we will offer bundled avionics + panel packages at competitive pricing.

For now, customers may supply their own avionics, or we can source equipment at standard retail pricing. We design the panel and wiring harness around the exact equipment selected for your project. We're also happy to advise on model selection and compatibility.

For a complete, fully assembled panel, having the avionics on hand is not required, but it is recommended as it can help ensure the most precise fitment, wiring, and integration.

For design-only or bare panel orders, physical equipment is not required. We design from official installation manuals, cutout templates, and manufacturer CAD data. Final design approval is based on confirmed model selections to ensure full compatibility.

Every aircraft is unique. Panel size, material, finish, avionics selection, wiring complexity, and optional upgrades all affect the final cost. Because no two builds are identical, we provide custom quotes tailored to your exact requirements rather than one-size-fits-all pricing.

Yes. A 50% deposit is required to begin fabrication after design approval. The remaining balance is due before shipment. CAD-only orders require full payment before file delivery.

Payments are processed through a secure invoicing system with support for all major credit and debit cards (Visa, Mastercard, American Express, etc.). After order confirmation, you will receive a detailed invoice and secure payment link.

Before fabrication: Deposits are generally refundable minus any design, engineering, or configuration work completed to date, as reflected in the project record.

After fabrication begins: Deposits become non-refundable due to committed materials, allocated components, and production labor tied to your approved project scope.

Completed panels: Return or refund eligibility is evaluated on a case-by-case basis, taking into account the approved project scope, configuration, and condition of the delivered panel. Custom or configuration-specific items, including engraved components, are generally non-returnable.

Yes. Under FAA regulations (14 CFR §21.191), the builder/owner of an amateur-built experimental aircraft is considered the "manufacturer" and has broad authority to install avionics and electrical systems. Our panels are designed specifically for this category of aircraft.

The builder is responsible for ensuring compliance with their operating limitations and airworthiness requirements.

Yes, ADS-B Out is required in Class B, Class C, and certain other controlled airspace. We incorporate ADS-B compliance into your panel design and wiring harness. Common experimental options include:

• Dynon (SV-ADSB-472 with SkyView systems)
• Garmin GTX 35R / 45R (remote) or GTX 335 / 345
• uAvionix skyBeacon / tailBeacon / echoUAT
• Trig TT22 / TT31 transponders
• Appareo Stratus ESG / ESX
• FreeFlight Rangr series

Yes, we highly recommend it. EAA Technical Counselors provide free, expert guidance to builders and can review your avionics installation for safety and compliance. A DAR (Designated Airworthiness Representative) will also inspect your aircraft before issuing your airworthiness certificate.

We provide wiring diagrams, documentation, and build details to support your inspection.

Yes, we ship completed avionics panels and wiring harnesses to all 50 U.S. states. International shipping is available on a case-by-case basis; contact us for a quote that includes shipping, insurance, and any applicable customs or duties.

Panels are packaged in foam-lined crates or custom protective packaging to ensure safe transport and prevent damage during transit.

Yes, local pickup is available. Contact us to arrange pickup.

We stand behind the quality and workmanship of every panel we build. If anything arrives damaged or does not match your approved design, contact us promptly with photos and a description of the issue. Each case is reviewed against the approved project scope, project record, and the specifics of the situation to determine the appropriate resolution.

Every panel is fully documented and photographed before shipment to ensure accuracy and to support efficient issue review and resolution.