As others have done, I decided to run conduit in the cabin top A pillars. This will allow me easily route wires into the overhead console and better finish the interior transition to the windshield.
I started by roughing up the fiberglass and tacking conduit into place with super glue.
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221230_2311254851570412065238874726.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221230_2311372064127505810721313040.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221230_2311477766802366885628009421.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221230_2311507026373712663769245757.jpg)
I then fashioned some dams from painters tape and filled the area with two-part expanding foam. This didn’t go quite as I had planned as there is almost no working time.
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221231_0048267452829719063681859126.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221231_0048386275153747469374957894.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221231_0048435079130306472584600423.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221231_00485059265579301858107018.jpg)
After it cured I carved it back with a knife, sandpaper, and a file. I then mixed up some West Systems microlight filler to fill any remaining voids.
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221231_0525157723210468439582436248.jpg)
I wanted to keep the pillars as low profile as possible to avoid limiting the viewing angles out of the windshield. The conduit was a bit thicker than the cavity in places so I compressed it into an oval shape with blocks covered in packing tape while the filler cured.
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221231_0525278875779746624109972071.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221231_052533666249314972874635949.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221231_0525556825461734483781569630.jpg)
After sanding, I added a layer of micro to create the general profile I wanted.
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230103_0049428561270114297166781521.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230103_0049502347036769980778643510.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230103_00494693174331964634518353.jpg)
This was then sanded back to the profile that I was looking for (I used a 3d printed profile as a guide while sanding).
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230108_0200016463478380003054817293.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230108_0200077432633491203240885038.jpg)
The final profile came out really well and this will do for now as I have more work to do on the overhead console before epoxying it into place.
I plan to add a couple of layers of glass before final finishing to ensure I have a solid surface before final blending with the overhead console.