Sounds like something from Formula 1 – but has to do with my overhead.

I have spend countless hours/days/weeks/months getting gauges and 7-segments working on my overhead. Latest focus has been on the 3 panels with 7-segments displays: Altitude, IRS and Electrical.

Every time I have had one of the panels out, I have made an enclosure for the panel before re-mounting it. By now this is mass production. The reason is an attempt to limit the messy wiring. With an enclosure wires inside the box is hidden. And cables to the box can be bundled hopefully making a nice looking wiring on the backsire. Furthermore using connectors makes it easier to take out a panel at a later point.

The method is relative simple. It is designed in Fusion 360 and 3d printed. Because it is a relative simple design even I am able to do it in Fusion 360. I make a box that fits the mounting hole in the overhead and the a backside that fits. The backside is designed with holes for the needed connectors. The box is 80 mm high which leaves room inside the box for wires and fits with my “hex m3 brass extenders”. So the box is standard measures. The back / lid needs a bit more care because it is individual designed for the needed connectors. Furthermore making all boxes the same height makes it easier to do the bundling of wires behind the overhead.

For connectors I mainly use:
DB9 / DB15 / DB25 for switches and annunciators.
2-pin aviation plugs for backlight
Large cannon-plugs for 7-segments displays
8-pin aviation-plugs for stepper motor driven gauges.
3-pin dupont connetors for servo driven gauges

Of course this solution is only possible if you have an overhead with big mounting holes. My overhead is SimWorld. But other companies like Cockpit Sim Parts has a metal frame with cutouts for switches and backlightning. In that case this is not possible.