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FOR SALE – TWO VirtualFly SoloGA Flight Simulator COMBOS with YOKO+ yoke, TQ6+ throttle quadrant, and RUDDO+ rudder pedals, $6,000 EACH. Purchased new in 2022 for our business, very lightly used for just a handful of tradeshows (Sun N Fun, Oshkosh, AOPA) and nothing else. STILL UNDER WARRANTY for more than a year! Less than 100 hrs each on them but no longer needed for these events so here’s a great bargain! We paid more than $10,000 each new but offering these essentially new units at a steep discount! SoloGA glass touchpanels can create accurate "six pack" cockpit gauge layouts for Cessna 172/182, Beech Baron, King Air 350, Mooney Bravo, and others and has those aircraft loaded. Panel switches and TQ6+ throttle configured for single- and double-engine birds. Both units come complete with mid-tower gaming PC, 40” TV monitor, variable adjust monitor stand, keyboard, mouse, remote, and table clamps. All Flight Controls (panel, yoke, throttle, and pedals) fully compatible with XBox as well -- all USB! Prepar3D loaded but all hardware compatible with MSFS and X-Plane as well. Ships fully assembled in crate, just plug the RUDDO+ USB into the PC, turn it on, and fly! Fantastic unit for a home Cessna sim, education use, or demonstration. VirtualFly hardware is BUILT TO LAST – my organization has been using VF sims for nearly a decade in educational situations with thousands of middle-school students per year with no hardware fails or replacements necessary yet. Great service available with English-speaking rep I know personally who visits the U.S. often. Buyer will pay shipping, will ship professionally palletized to your location via LTL Freight inside the U.S., usually $500 - $700 from Chicago. Will provide quote prior to shipping and ship COD.
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Version 1.0.0
13 downloads
I was scrolling through the requests for liveries this morning and came across an exciting one: Several people wanted the cockpit of the Cessna 172 in beige. So I immediately started experimenting. And after a few minutes it worked. This add-on changes the color of the cockpit from grey to beige on all variants of the C172. Please note that only by deleting the mod, the cockpit becomes gray again. There is no option to change this in the video game. How to install: (0. Delete older versions of this add-on.) 1. Download the ZIP-file. 2. Open the ZIP-file. There should be a folder called "nfm-c172-beigecockpit". 3. Drop this folder into your MSFS community folder. 4. Start MSFS. The add-on should work now. If you have any suggestions, ideas for improvement, criticism or questions, please write a comment or contact me via direct message. To discover my other products, you can either visit my profile on Flightsim.to or my website. My Website To find out the latest news about my upcoming add-ons and products, follow me on Instagram! My Instagram Have fun! -
FSX Graphics Issue with Freeware Thomas Ruth A330
epopchock posted a topic in FSX General Discussion
Since yesterday, I have been having graphics issues when using the Thomas Ruth A330 aircraft. When I change from window mode to full screen (or vice versa) my graphics look like this This happens at LAX with this aircraft. I have also tested this aircraft and a Hawaiian A330 at Seattle Airport, and the same thing happens. I tried the HIGHMEMFIX=1 solution from a different forum, but that has not corrected my problem. I was trying to do a flight from Los Angeles to Fiji when this happened, and I have no idea what could be wrong. I'm open to any advice or solutions you can give me. Here's a copy of my fsx config and my system specs, if you need that: [bufferPools] PoolSize=10000000 [sOUND] AmbientUIMusicVolume=-6.000000 SOUND=1 SOUND_QUALITY=2 SOUND_LOD=0 UISound=1 AmbientUI=0 PrimaryDevice={DEF00000-9C6D-47ED-AAF1-4DDA8F2B5C03} VoiceDevice={DEF00002-9C6D-47ED-AAF1-4DDA8F2B5C03} SOUND_FADER1=0.660000 SOUND_FADER2=0.600000 SOUND_FADER3=0.500000 SOUND_FADER4=0.600000 AmbientUIMusic=FSX02 [Display] ChangeTime=4.000000 TransitionTime=4.000000 ActiveWindowTitleTextColor=255,255,255 ActiveWindowTitleBackGroundColor=0,28,140,64 NonActiveWindowTitleTextColor=255,255,255 NonActiveWindowTitleBackGroundColor=24,33,87,64 InfoUpperRightTextColor=255,0,0 InfoUpperRightBackGroundColor=0,0,0,0 InfoLowerLeftTextColor=255,255,255 InfoLowerLeftBackGroundColor=255,0,0,128 InfoLowerRightTextColor=255,255,255 InfoLowerRightBackGroundColor=255,0,0,128 InfoBrakesEnable=True InfoParkingBrakesEnable=True InfoPauseEnable=True InfoSlewEnable=True InfoStallEnable=True InfoOverspeedEnable=True BLOOM_EFFECTS=0 SKINNED_ANIMATIONS=1 TEXTURE_BANDWIDTH_MULT=21 UPPER_FRAMERATE_LIMIT=30 WideViewAspect=True [Main] HideInfoText=0 User Objects=Airplane, Helicopter SimObjectPaths.0=SimObjects\Airplanes SimObjectPaths.1=SimObjects\Rotorcraft SimObjectPaths.2=SimObjects\GroundVehicles SimObjectPaths.3=SimObjects\Boats SimObjectPaths.4=SimObjects\Animals SimObjectPaths.5=SimObjects\Misc Maximized=1 Location=107,97,1169,859,\\.\DISPLAY1 HideMenuNormal=0 HideMenuFullscreen=1 ProcSpeed=7293 PerfBucket=5 [PANELS] IMAGE_QUALITY=1 QUICKTIPS=1 PANEL_OPACITY=100 PANEL_MASKING=1 PANEL_STRETCHING=1 UNITS_OF_MEASURE=0 DEFAULT_VIEW=0 [Weather] WindshieldPrecipitationEffects=1 MinGustTime=10 MaxGustTime=500 MinGustRampSpeed=1 MaxGustRampSpeed=200 MinVarTime=5 MaxVarTime=50 MinVarRampSpeed=10 MaxVarRampSpeed=75 TurbulenceScale=0.800000 WeatherServerAddress=fs2k.zone.com WeatherServerPort=80 WeatherGraphDataInDialog=0 AdjustForMagVarInDialog=1 DynamicWeather=2 DownloadWindsAloft=0 DisableTurbulence=0 CLOUD_DRAW_DISTANCE=4 DETAILED_CLOUDS=1 CLOUD_COVERAGE_DENSITY=8 THERMAL_VISUALS=0 [DISPLAY.Device.NVIDIA GeForce 8200.0] Mode=1024x768x32 [CONTROLS] Controls_Default=Standard Controls_Current=Standard KBDAIL=64 KBDELEV=64 KBDRUD=64 [GRAPHICS] SHADER_CACHE_PRIMED=1693458432 TEXTURE_MAX_LOAD=512 NUM_LIGHTS=8 AIRCRAFT_SHADOWS=1 AIRCRAFT_REFLECTIONS=1 COCKPIT_HIGH_LOD=1 LANDING_LIGHTS=1 AC_SELF_SHADOW=0 EFFECTS_QUALITY=1 GROUND_SHADOWS=0 TEXTURE_QUALITY=3 IMAGE_QUALITY=0 HIGHMEMFIX=1 See_Self=1 Text_Scroll=1 SHADER_CACHE_PRIMED_10=1693458432 D3D10=0 [TextInfo.1] Latitude=1,1 Longitude=1,2 Altitude=1,3 Heading=1,4 AirSpeed=1,5 WindDirectionAndSpeed=1,6 [TextInfo.2] FrameRate=1,1 LockedFrameRate=1,2 GForce=1,3 FuelPercentage=1,4 [TextInfo.3] Latitude=1,1 Longitude=1,2 Altitude=1,3 Heading=1,4 AirSpeed=1,5 WindDirectionAndSpeed=1,6 FrameRate=2,1 LockedFrameRate=2,2 GForce=2,3 FuelPercentage=2,4 [slewTextInfo.1] Latitude=1,1 Longitude=1,2 Altitude=1,3 Heading=1,4 AirSpeed=1,5 [slewTextInfo.2] FrameRate=1,1 LockedFrameRate=1,2 [slewTextInfo.3] Latitude=1,1 Longitude=1,2 Altitude=1,3 Heading=1,4 AirSpeed=1,5 FrameRate=2,1 LockedFrameRate=2,2 [DynamicHeadMovement] LonAccelOnHeadLon=-0.020000 LonAccelOnHeadPitch=-0.010000 RollAccelOnHeadLat=0.010000 YawAccelOnHeadLat=-0.100000 RollAccelOnHeadRoll=0.100000 MaxHeadAngle=5.000000 MaxHeadOffset=0.300000 HeadMoveTimeConstant=1.000000 [VirtualCopilot] VirtualCopilotActive=1 [uSERINTERFACE] PageID=4 SHOW_MISSION_CAPTIONS=0 PAUSE_ON_LOST_FOCUS=1 PROMPT_ON_EXIT=1 SITUATION=FLIGHTS\OTHER\FLTSIM Map_Orientation=2 OpenATCOnCreate=0 ShowAllACPaintSchemes=1 SelectAircraftManufacturer=All SelectAircraftPublisher=All SelectAircraftType=All DisplayFuelAsWeight=1 [ATC] ShowATCText=1 COMM_MSG_NONE_COLOR=FFFFFFFF COMM_MSG_ATC_USER_COLOR=FFB6FFB6 COMM_MSG_USER_ATC_COLOR=FFFFD21B COMM_MSG_ATC_AI_COLOR=FF00FF00 COMM_MSG_AI_ATC_COLOR=FFFF7840 AutoOpenAirTrafficWindow=1 UsePilotVoice=1 PilotVoice=0 [PointOfInterestSystem] CycleSetting=0 [sCENERY] LENSFLARE=0 DAWN_DUSK_SMOOTHING=1 IMAGE_COMPLEXITY=5 [TrafficManager] AirlineDensity=72 GADensity=74 FreewayDensity=70 ShipsAndFerriesDensity=54 LeisureBoatsDensity=62 IFROnly=0 AIRPORT_SCENERY_DENSITY=4 [TERRAIN] LOD_RADIUS=4.500000 MESH_COMPLEXITY=30 MESH_RESOLUTION=21 TEXTURE_RESOLUTION=26 AUTOGEN_DENSITY=2 DETAIL_TEXTURE=1 WATER_EFFECTS=4 [AContain] ShowLabels=1 ShowUserLabel=0 ShowLabelManufacturer=1 ShowLabelModel=1 ShowLabelTailNumber=0 ShowLabelDistance=1 ShowLabelAltitude=1 ShowLabelAirline=0 ShowLabelAirlineAndFlightNumber=0 ShowLabelFlightPlan=0 ShowLabelContainerId=0 ShowLabelAirspeed=0 ShowLabelHeading=0 LabelDelay=1000 LabelColor=FFFF0000 [iNTERNATIONAL] ASLAT=2 ASLON=1 MEASURE=0 [REALISM] PFactor=0.000000 Torque=0.000000 GyroEffect=0.000000 CrashTolerance=0.000000 General=0.000000 UnlimitedFuel=False TrueAirspeed=False AutoCoord=False RealMixture=False StressDamage=False GEffect=False ManualLights=False GyroDrift=False CrashWithDyn=False CrashDetection=False AutoTrim=False [sIM] SYSCLOCK=1 [sTARTUP] DEMO=0 SHOW_OPENING_SCREEN=1 STARTUP_DEMO= LoadWindow=1 [FACILITIES] COUNTRY= STATE=California CITY=Los Angeles GTL_BUTTON=3485 [Misc] Com_Rate=7 [DISPLAY.Device.NVIDIA GeForce 8200.0.0] Mode=1024x768x32
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Join me in this short local flight, where you can control the camera angle as you wish. Use your phone, mouse or remote control - based on your device. Filmed with a GoPro MAX in 5K Ultra HD. -
/images/notams/notams21/pmdg1209.jpgToday in their forums, PMDG have shared some new preview screenshots of the cockpit of their Boeing 737 for MSFS 2020. The shots show offthe improved appearance of instruments, switches, etc. attributed to theimproved lighting model in MSFS. Source
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/images/notams/notams21/dino1012/indiafoxtecho1.jpgHere are the most requested screen shots of the new virtualcockpit model. While the external models are basically (substantial)upgrades of our P3D models, we decided to redo the cockpit entirelyfrom scratch: this required a lot of work and research (if anything tohunt for some hard-to-find details) - but we think it was worth theeffort. /images/notams/notams21/dino1012/indiafoxtecho2.jpg /images/notams/notams21/dino1012/indiafoxtecho3.jpgWe'll keep you posted on Beta test availability (hopefully not toofar in the future) and release date as soon as possible. In any casewe are not releasing anything (including updates to our existingproducts) before the next Sim Update is deployed. Source
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Join me in this short local flight, where you can control the camera angle as you wish. Use your phone, mouse or remote control - based on your device. Filmed with a GoPro MAX in 5K Ultra HD.
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A short video from our flight last weekend in a Cessna 172. Flying VFR over fjords and valleys in southwestern Norway. ATC communication is included, and English captions are available.
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Hi everyone. I created a Boeing 747 cockpit out of LEGO and submitted it to the LEGO Ideas program (which can use your support). There are quite a few features including moving/linked controls, sliding seats, detailed interior and matching fuselage. It has 1,874 parts. LEGO Ideas is a program where if an idea reaches 10,000 supporters (ie a free vote) then LEGO might make it into an actual LEGO set. If that happened, well there is no reason why LEGO couldn't make an entire series out of this with different aircraft, or anything that has a cockpit (shuttles, heavy machinery, etc). Supporting is super easy, just go here, bit.ly/747Cockpit click Support and log in using a free LEGO Ideas account. I really appreciate it and hope you like it.
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Hi! I'm a private pilot in Norway. I made a video of my last flight, hope you will like it! Best enjoyed on a 4K device :cool: Let me know what you think.
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Just wanted to share my upgraded night lighting...lol...see around 8:00
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/images/notams/notams19/just1014.jpgThose eagerly awaiting the chance to fly an early model Boeing 747will enjoy learning more about 747 Classic now in developmentby Just Flight. Their new video shows lead developer Robin Goodchildpresenting a detailed overview of the 747 Classic development cycle. Product Page About The 747 ClassicJust Flight are excited to bring you the early models of the iconicJumbo Jet with its instantly recognisable upper deck and four-enginewidebody configuration. 747 Classic includes the 747-100 and -200passenger variants and the 747-200F cargo variant. The 747-100 wasfirst flown in 1969, revolutionising domestic air travel, and the -200variant followed in 1970 with a range of more powerful engine typesand increased fuel capacity, providing an intercontinental range. The-200F cargo variant entered service shortly afterwards, offering asignificant freight-carrying capability to cargo operators.
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/images/notams/notams19/just0714/747classic-1.jpgA closer look at some of the panel details! Now that our forthcoming 747 Classic add-on for P3D and FSX is inthe final stages of development, we've been spending a lot of timechecking and testing countless features and functions in the virtualcockpit. Wherever we look, we've been hugely impressed by the realismof all the instruments, panels and cockpit features. Hats off to the modelling team at 3D Reach, who really have createda superbly detailed cockpit! A selection of cockpit items are shown below if you'd like to get acloser look at them for yourself. /images/notams/notams19/just0819/just-flight-747-classic-06.jpg /images/notams/notams19/just0819/just-flight-747-classic-05.jpg /images/notams/notams19/just0819/just-flight-747-classic-04.jpg /images/notams/notams19/just0819/just-flight-747-classic-03.jpg /images/notams/notams19/just0819/just-flight-747-classic-02.jpg /images/notams/notams19/just0819/just-flight-747-classic-01.jpgSource
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With FsXpand you can build your own panels for your sim. FsXPand runs on your simulator pc with FSUIPC. It connects to FsClient running on one or more PC's (or even the FS PC). New in this release: - Online feature: You can now track your flight by switching the feature on in FsXpand and then go to https://flyware.nl/track - Added Mooney Bravo cockpit - Added Kingair 200 en 350 engine gauges - Added prop sync gauge Improvements: - QNH (Altimeter) can now be set separately for Captain and F/O - The ADF indicator will change now needles VOR1/VOR2 and ADF1/ADF2. A separate key command can be set for this purpose. - Night lighting is now available. You can set you intensity and tone of colour. Follows your light switch. - For those who run more than 1 client on a machine: You can set the name of the client so you can easily identify it. - Performance upgraded You can try out FsXpand for free. Why would you choose FsXpand? - Flexibility: With most panel suites, you buy per aircraft type. With FsXpand, you have several cockpits at once (more to come), no need to switch to other software if you change your a/c type. - Versatility: You can make your own selection of gauges/panels, drag, resize over 100 different networked gauges. Works with the most popular sims. - Adaptability: Even modify your gauges using the Gauge Editor (expert option). - Portability: A system change does not require you to renew the license. Neither is there a limit to the amount of clients/panels you want to run. The license is valid for 1 Local Area network (255.255.255.0). 1 FsXPand (server component), clients unlimited. https://flyware.nl
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/images/notams/notams19/ware0607.jpgFlyware.nl has the ultimate software for cockpit builders. Select,drag, resize over 100 different networked gauges - Basic 6, Navigation,Piston, Turboprop, Jet or Generic gauges - Glass panels for 737, EICASfor 747 and Fokker 70/100. Also includes FMS. It is designed to workwith FSX, FS2004, X-Plane, and Prepar3D. We will present this year a sequence of updates and extensions,some of them minor, some extensive. One of the new updates contains a Mooney Bravo panel, as as well as a set of new engine gauges for the Kingair 200 and 350. Added FeaturesQNH will be 2-sided, so the F/O can set his own altimeter (transition altitude/height).The ADF indicator will change now needles VOR1/VOR2 and ADF1/ADF2. A separate key command can be set for this purpose.Night lighting is now available. You can set you intensity and tone of colour.For those who run more than 1 client on a machine: You can set the name of the client so you can easily identify it.The new Radar Altitude Indicator (Collins) shows an amber Decision Height light. And of course a bug to set.flyware.nl
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Flyware.nl has the ultimate software for cockpit builders. Select, Drag,Resize over 100 different networked gauges - Basic 6, Navigation, Piston, Turboprop, Jet or Generic gauges - Glass panels for 737, EICAS for 747 & Fokker 70/100. Also includes FMS. It is designed to work with FsX, Fs2004, X-Plane, and Prepar3D We will present this year a sequence of updates and extensions, some of them minor, some extensive. One of the new updates contains a Mooney Bravo panel, as as well as a set of new engine gauges for the Kingair 200 and 350. Added features: â—¦ QNH will be 2-sided, so the F/O can set his own altimeter (transition altitude/height). â—¦ The ADF indicator will change now needles VOR1/VOR2 and ADF1/ADF2. A separate key command can be set for this purpose. â—¦ Night lighting is now available. You can set you intensity and tone of colour. â—¦ For those who run more than 1 client on a machine: You can set the name of the client so you can easily identify it. â—¦ The new Radar Altitude Indicator (Collins) shows an amber Decision Height light. And of course a bug to set. https://flyware.nl
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Hello Since my PMDG 737 didn't work because I don't have the activation key, and it is too expensive to get a new one, and since I downloaded it for the realism (Virtual Cockpit and Cabin and lights), I was looking the whole internet for this feature to add (realistic cockpit and virtual cabin with views of the wing from the windows and realistic lights) to my Default 737-800 for free, because the default 737-800 looks pretty boring to me: Unrealistic cockpit and lights (internal and external lights), no view of the wings from the cockpit windows and no virtual cabin. Does anyone know where I can get that feature for the Default 737-800? Thanks in advantage -
Project Home Cockpit By Rays Aviation Intro Have you ever wanted to expand your flightsim experience? Ever since I started virtual flying I felt like something was missing - an environment, the unique smells, sounds and the look and feel when you enter a cockpit, the excitement of firing up the engine and taxiing to the runway for take-off and then the awesome feeling when you can see the wings starting to bend upwards and you lift off the ground. Flight simulators over the last decade has increased greatly and the realism presented for a flight simmer today is really good - however the real feeling of flying an aircraft just isn't the same sitting in a normal chair, looking at a 20" monitor and controlling a Boeing 737 with a mouse and a basic 3-axis joystick (meaning controlling the rudders by twisting the joystick). There are today several ways in which the simmer can improve their experience - some rather extreme and very costly, but to gain an improved experience does not mean to build a $30 million simulator as the simulators used for type ratings at the professional airlines; it can just might as well be a home built cockpit with wooden frames, a few realistic modules and the experience has already been lifted to a higher level. I started to gain interest in building a home cockpit but thought that it was a too complex project for me, therefore I started out with designing and building a toggle switch panel, just to see if I was able to do that and the result was actually four different toggle switch/rotator switch panels which were all working perfectly. Hereafter I indeed got very interested and setup a new project - building a console/pedestal of various modules etc. This new project I also finished without problems and I actually used that console for quite a while when testing new hardware. Now, after doing these two projects I was really very interested in starting up a new project - this time I wanted to expand my knowledge and test my skills doing a more complex project. I designed a project with the goal of building a MiP (main instrument panel) - not a replica of any aircraft but instead a MiP of my own creation; however everything has a tendency of expanding similar to my project toggle switch panel, so when I had designed my project MiP it was actually not only a project containing a MiP, but instead a complete home cockpit. My name is Raymond Andersen and some of you might know me better as Rays Aviation - This is a story about my latest project of building a home cockpit of my own design. Scoping & Designing The first thing I did when I decided to start this project was trying to define what I actually wanted to do and what the goal should be. If I needed progress goals to keep me going and which additional challenges I wanted to give myself during the project. What I wanted to do was to build a home cockpit which was not a replica of any kind, which included most of the hardware units that I had previously tested and reviewed, which could be connected to just one single computer, which was not a turn-key solution, which included modules or products from at least ten different suppliers and which would feature both a glass cockpit function but also the old standard gauges. The home cockpit should of course be compatible with FSX since that is the flight simulator platform that I am using, and the controls should be HOTAS throttle and stick which I prefer. Cockpit of own creation -- not a replica but okay to use replica modules, etc. Use most of the hardware that I already had in my portfolio Setup should only be featuring one computer (would cause issues in regards to the video inputs but I had a plan...) The MiP should be both a glass cockpit but also include old fashioned gauges Compatible with Microsoft FSX Controls had to be HOTAS throttle and stick configuration Use products from at least ten different suppliers Must NOT be a turn-key solution I decided that I wanted to build the cockpit as a single seat cockpit since I would be using the HOTAS configuration - of course the HOTAS configuration could also apply in a twin seated cockpit but normally this configuration is seen and used in single seated configurations. When creating a single seated cockpit I now did not have to build a pedestal which is normally found between the pilots in a twin seated cockpit. Instead I had to build both a left side and right side console supporting a variety of modules and functions together with the MiP. I decided that I did not want to build an overhead for this home cockpit (could be an additional project in the future), so the plan to build was only: Left side console Right side console Main Instrument Panel (MiP) Support for rudder Support for stick mounted on seat I started by placing all my current hardware on the floor and there from marking each unit with either MiP, left console, right console, seat, floor, etc. so that I could gain an overview of which units I wanted to place where. I hereafter marked an area on the floor covering both the left and right console and started placing the units where I thought it would be the most logical to place them. I did the same with the units for the MiP and quickly ended up with 10 or 15 different layouts. Now I just had to choose which layout would fit my idea the best. Now I selected which layout I wanted to go with and laid out all modules on the floor for both consoles and the MiP, took a picture and slept on the idea for a few days. I looked at the picture a huge number of times to try and see how it could be better - it was as something was missing and I wanted to make it more complex and include more switches, etc. This ended up in me actually designing additional modules for the cockpit - well front plates that could support some different switches. I started searching for switches that would fit my design and idea. I wanted to give my cockpit a touch of a Boeing 737 besides the replica modules that I had, so I went to Opencockpits webshop and ordered some Boeing B737 toggle switches which have the characteristic white cap. I also searched DX.com (Deal Extreme) for additional small toggle switches and click switches - I found some various switches and ordered them. Now that all was ordered I also had the correct measurements for the holes that needed to be cut in the front plates. I updated my drawings and mailed them to one of my contacts "Hedensted Maskinfabrik" who has several machines that are able to laser cut metal - He quickly put my drawings into his production line and the output was some excellent cut aluminum front plates of my own creation. Previously I had built some toggle switch panels so this time it was quite simple and I knew how to proceed. I now had the front panels and the switches that should be a part of the additional self-designed modules, so all I now needed was to connect them to some PCBs - I had some PCBs from Desktop Aviator from my previous project that had some free connection pins, and additionally I also had several PCBs from Opencockpits that also could be used for connecting these new modules - the output was a combination of both and I now had a great variety of modules for the complete setup. Additionally I also had to figure out how and what kind of materials I wanted to use when building the cockpit. Should the frames be built of plastic, metal or wood and if metal then what kind of metal... I had the same issue if I was to choose wood as the material - what size, form and quality should it then be. I have no experience working with metal as steel or aluminum which I thought would be the ideal material for this project - this was however also very expensive and I would need a lot of outside help just to get the project started, so my solution ended up being wood for the frames in the cockpit.Since I am actually an office working guy my skills working with wood, screws, etc. is quite limited, but I had ideas and dedication and I was not afraid to try. One thing was the frames but what about the MiP - I had previously used plywood as a top for a console, but to be honest I found that solution to be a bad idea because the plywood has a very rough surface. That combined with the fact that I did not want to use aluminum or steel gave me a challenge and I had to find a completely different material to use. I found a Danish web site created by a person who had built a Boeing B737 captains side cockpit and he had used a material called FoamAlux, which is foamed PVC (polyvinylchloride) that has the strength like plywood, or actually probably even better, and the surface is super smooth. To process this material was described to be very easy - only using a Stanley knife or similar, but that I later found out would be a modification of reality, or maybe that was because the person who had used this material, had used a thinner piece than what I would later on use. I selected the FoamAlux as material for the MiP and ordered at the local DIY shop one plate with a thickness of 10mm - this was way to think for me to process simply by using the Stanley knife, so I had to use a small manual saw and also an electrical saw to ease the processing, no problem though - it's like the phrase "Learning by Doing". Now my only concern in regards to materials was the glare wings and top + sides of the consoles - my first idea was to use the FoamAlux for that also, but that would be an incredible expensive solution so I had to find a different solution. I went to the local DIY shop and looked around. I found various possible solutions as 3-5mm FoamAlux, plywood, hardened plastics such as Plexiglas and acrylic plates, various hardened foam products and the Kapa Graph plate which is foamed carton in 5mm. The Kapa Graph material was already colored black, easy to process, price wise very fair and it had enough stability for what I needed - the few places where I needed additional stability I could support the Kapa Graph with wood on the back side + all screws mounted into the Kapa Graph would also be fastened into the wood behind because the density of the Kapa Graph is not sufficient enough to withhold screws properly. The Build I started out by building the frames for the left and right console, and I remembered to make sure that the left console had a support for the dual throttle that I was going to place there. That was a very essential part and something that I easily could have overlooked until I were to place the throttle to the setup...yea. After building the two consoles I laid down the FoamAlux plate and started placing various modules on top of it - just to get a picture of what it would look like and get an overview of the complete size of the MiP. Next step was to start the marking of the modules, etc. on the FoamAlux plate together with the edges of the MiP, so that I could start the process of cutting the plate into the correct form including mounting holes for the various modules, TFTs and frames, etc. This part was actually quite easy and I found the FoamAlux to be a nice material to process. It was a material that had a good strength but still was very easy to cut through using a small manual saw. To do the finish and clean the edges I used the Stanley knife. When I had finished the cutting of holes and shaping the MiP I started building the stand for the MiP. Since I had already build the left and right console I could now also calculate which height the MiP would be mounted at - this gave me my total height of the support for the MiP stand. Actually the support and stand for the MiP was built extremely simply but still very stable and when finished I mounted the MiP onto the stand. The next step was painting the MiP - I had looked at various colors but liked the Boeing B737 style using the RAL7011 grey. The FoamAlux surface is very smooth and thereby it turned out to be a little tricky to paint - what I did was actually to paint it several times to get the very smooth and clean surface that I wanted, but that also meant that the MiP suddenly looked brand new and what I actually wanted was for it more to look a little bit used instead. The way I solved this was to paint the MiP a fourth time, but instead of letting the paint dry out 100% I took the paint roll, washed it and dried it about 70% so that the roll still contained moisture, and then used the paint roll on the not completely dried MiP - the effect this "technique" gave was a MiP with a lot of color shadings that was randomly placed and gave the impression that the MiP was old and used but still in good condition. I had now finished the three main components of the home cockpit and I started the process of assembling the left and right console with the MiP. This was really an easy job because I had chosen to use wood instead of metal, so the assembly was done using ordinary torx screws and it did not take that much time. I had an issue though regarding the mounting of the gear lever into the MiP... The gear lever is a replica of the gear lever found in a Boeing 737, and the MiP in the B737 is tilted 150 backwards and this gave me a challenge because my MiP was completely vertical. The solution that I came up with was to even out the 150 by adding wedges made by the Kapa Graph and mounting that onto the button of the gear lever frame behind the MiP. The remaining modules and parts for the MiP were mounted without any problems - the MCP and EFIS fitted perfectly into the holes that I had cut and the MCP could also be fastened with four screws (one in each corner). The two front plates for the gear lever was also super easy to mount, but I came to think about when looking at the gear lever, I could actually see through the gear lever frames and thereby seeing whatever was behind the MiP there. This I was not satisfied with, so I had to find a solution where I could close the gab when operating the gear lever. The solution was to use two pieces of rubber bands (not soft but fairly hardened) and mount them on each side of the gear lever on the backside of the MiP - the result of this was that when the gear lever was down the gap in the top was closed and vice versa. This was a quite easy and very cheap solution that worked perfectly. Adding the Flight Illusion gauges was also a bit of a challenge because making round holes with a diameter of 80mm without proper tools was quite difficult - I searched the local DIY store to see if I could find some drills or similar with that diameter, but unfortunately I was not that lucky. My solution for that issue was to contact one of my professional contacts, Silkeborg Plast, who has machines that can process plastic plates into whatever you want. His machine could cut/drill all 3 holes to perfection similar with a laser cutting machine processing steel or aluminum - the result was excellent and all I had to do was to make a rectangular hole, mount the gauges into the plastic frame and mount the complete unit into the MiP using just four corner screws. The last pieces of the MiP was the TFTs which should be mounted on the backside of the MiP and the two MFD frames that should be mounted on the front side but the wires should connect behind the MiP. This was no problem - the MFDs could be mounted just by using a little bit of glue and for the cables I had drilled two small openings at the bottom and center of each window. Next was mounting the TFTs and this turned out to be extremely easy as well - I could use the support that I had made for the MiP to also support the TFTs - all that was needed additionally was two screws for each TFT which was screwed into the backside of the MiP just below the TFTs, meaning that the TFTs would be resting on the screws and at the same time being supported by the MiP support (the H-frame). Now the basic MiP was created and I turned my focus onto the left and right console - I took some Kapa Graph plates and started measuring the modules that was to be used and then drawing that onto the Kapa Graph - the process itself was done using a Stanley knife, a measuring pin, a pencil and a straight piece of metal (to make sure the lines were perfect). This was super easy and really did not take much time - so suddenly I had all tops including modules etc. mounted on the consoles. After the tops were created and mounted I only remained to mount some Kapa Graph on the sides to close the consoles and create the cockpit look - this however I could not yet do because I had only mounted the various modules but they were not yet connected. Before I put my focus on the connection of everything I wanted to mount the rudder pedals - I wanted them to be one with the setup and not just some "loose" placed pedals which I previously have had some issues with. Before I created this cockpit the rudder pedals were just placed on the floor, but when using them then quite often the pedals moved out of place when applying rudder; really annoying! Therefore I mounted a wooden bar between the left and right leg-support for the MiP and on this bar I mounted the rudder pedals using screws. Now the rudder was indeed an integrated part of the setup, and if they were to move, it would mean that the complete setup would move (not likely to happen). Last challenge in the build was the control stick - the quick and dirty way of adding that to the setup would have been to mount it on the right side console... but I had a different idea. Modern military aircraft like the F-35 have the stick mounted on the right side of the cockpit as also does the F-16, but I more like the idea of placing the stick between the legs as in the F-18. This would however mean that I needed to create a floor support or some kind of integration with my chair. The floor support idea I discharged quickly and started thinking about ways to integrate the stick to my chair. The solution I came up with was a special cut metal plate that could be squeezed in between the brackets below the chair meaning no screws or anything were needed to mount the plate. In the metal plate were drilled four holes according to the locations of the four mounting screws used for my control stick and mounted it now was. Connecting Everything - Part 1 The build was great fun indeed but the next stage of the project would be even more fun, but also at times extremely frustrating it turned out to be - the connection of all modules and getting everything to work together. To get an overview I gathered everything into groups like controls, displays, PCB connected modules as well as what could be connected by VGA or HDMI or USB. Furthermore I also created a subgroup for the USB connections where I gathered USBs that could go into a hub and USBs that needed a direct connection. I found that the wiring was actually quite extensive and getting everything connected and working properly was a challenge in itself. The first step was to get the toggle switch panels connected properly to the PCBs before I would be able to connect them to the USBs - this was a nightmare - my own build panels featured a total of 6x 12-position, 1-pole rotator switches, 15 on/off click switches, 5 on/on toggle switches, 44 on/off toggle switches, 5 on/off/on toggle switches, 3 momentary on/off/on switches, a nose wheel steering module switch and the gear lever with 2 micro switches - color coding groups of wires I found to be a good idea! Finally I got all these wires connected to the supporting PCBs and could now set my focus on the connection of the USBs, VGA and HDMI, but... there was actually one more thing that I had to find a solution for. I had created a backlight function and had some various LEDs that needed power - some LEDs were connected through the PCBs from Opencockpits, so these I did not have to find a solution for, but the other LEDs that were a part of the setup together with the cooling fan for the Tracker IR5, I needed to have a power source for. That together with a 220v power source for the power converters used for some of the modules such as the CPFlight backlight function and the Opencockpits FMC v3 (CDU) and the Flight Illusion gauges. What I did was to build a 220v power station in the right console and from there I connected some power converters to build a low voltage power station, also placed in the right console - this low voltage power station contained output of both 5v and 12v - so now I had sufficient power to support all modules including the USB hubs needed. Before I connected the various cables I made a connection diagram so that I was sure that I had sufficient USB cables to support all functions. This diagram was actually quite complex and later in this article you will see the updated version (I had to make some changes due to some issues that came up). I had some modules such as the CP Flight MCP, the Opencockpits FMC v3, the ThrustMaster throttle and the Tracker IR5 which apparently needed a direct connection - furthermore I had the two TFTs which were to be connected through USBs (two USBs per TFT) and that took a whole lot of USB connections and power - and since I was only using one computer I was quite limited by the USB outputs available on the computer... That was however not my greatest concern - My computer only features two outputs on the video card but what I wanted was to use four independent screens on only two outputs. That at first seemed to be no problem since I could connect the TV to the HDMI and the FMC to the VGA and then the 2x TFTs through USBs - I found that I could do this and actually have four independent screens working. I was truly very excited and very happy because this issue had really been giving me some headaches. The reason for why you see connections for five screens in the control window is because my desktop screen is also connected to the computer using the second VGA connector - however this connector is only able to be used if either the primary VGA or the HDMI connector is disconnected (screen 2). However the four screens were all working perfectly ... well it seemed that they were... The problem did not show itself until I tried to load a flight in FSX - I could use the FSX normally when selecting aircraft, location, weather, etc. but when hitting the ALT+F keys and loading the scenery, FSX automatically converts to a full screen display and this terminated the idea of using the 2x USB TFTs because they just went black. I tried several times but I never could get this to work - the only solution I saw was to keep the flight within a re-sized window and that really killed the idea completely. I am no computer wizard and maybe there could be a solution for this that I am not aware of, but no matter what I tried the result was the same. This issue put me into a standstill and I didn't really know how to proceed. I thought about several solutions as to either purchase a new computer / videocard with additional outputs but this would be rather costly and I did not have that kind of funds to spend this late in the process - so what to do... The solution I came up with was to make a rather drastic change to the MiP - first I thought about excluding the FMC v3 and then adding a 20" monitor to the MiP which should be placed behind the MFDs but would still be able to function as a screen for both the MFDs. This idea seemed fair but on the other hand I didn't like to exclude the FMC v3 from the setup. I discharged that idea and instead went along with a second idea - adding an iPad as PFD/NG to the MiP. This however would mean a re-build of some parts of the MiP and also a compromise to my original idea about only one computer - but that I just had to do. Connecting Everything - Part 2 (Changing The MiP Layout) The reason for why I chose the second idea using the iPad was simply because I already had an iPad, meaning no additional investment, and I came to think about an app that I had previously tested. The IPObjects AirTrack v3.5 which is an app featuring both a PFD, NG, a combined PFD and NG together with EICAS, charts, MCP and much more - this is a very versatile piece of software that could run on the iPad, freeing up the video output for the FMC v3. The AirTrack is compatible with FSX and works on all aircraft as a stand-alone program that is fed with data from the aircraft within FSX. It features the PFD similar to the Boeing 737 style PFD and also a very good quality NG display. These could be shown independently or combined and the data transfer rate from FSX to AirTrack is superb providing a super smooth and perfectly aligned iPad PFD. Furthermore the App also features an MCP including standard functions of an MCP actually including the radios, etc. as well - however this was not my intention to use but the AirTrack also features a function to view airport charts, etc. and that combined with the fact that the iPad could be used as a touch screen, just made this solution very ideal. If I mounted my iPad in the MiP as being the glass cockpit and connected that to the computer with the IPObjects software to run the PFD, NG and EICAS I would have solved the issue without investing a lot of money. I know that I hereby also did compromise my original idea with only one computer, since the iPad is actually an independent computer, but this way I could keep the costs down and still get a realistic layout. During this change of the MiP I actually saw that I could, if I wanted to, fit 2x iPads into the MiP and hereby gaining both a PFD and NG in full size. However since the funds for the project were already spent, I had to limit myself to only one. I had one issue though with the iPad solution - I had already cut holes into the MiP and the iPad could not cover these holes so...... again what to do.... I did not want to do the process of re-building the complete MiP, so I created a frame around the iPad, which in my opinion came out quite okay, and this frame gives the look of the iPad being integrated into the MiP in a good way. Going along with this new idea I suddenly found my two TFT touch screens from Lilliput and my set of MFDs from ThrustMaster to be excluded from my project - this I didn't like and therefore I started to look for a solution where I could still use them in the setup, but now as an "option" and not a must. I looked at several real world cockpits to get ideas and I realized that a solution could be to add the TFTs as information screens containing a live feed from a third computer (primary was my FSX computer and secondary the iPad). I mounted the two TFTs including the MFDs on my right console and connected the TFTs to a third computer that could then be used to show SIDs on one screen and STARS or other airport charts on the other - this computer I then connected to the internet and I could now use Google to search for free airport charts to use for these screens. The MFDs I still connected to my primary computer to be able to assign various commands to the buttons and use them within FSX. A different solution could of course have been to connect these MFDs to the third computer, add a "library" of airport charts, SIDs, STARS etc. to an Excel spreadsheet and then write a few macros that could be assigned to the MFDs buttons; this would result in actually using the MFDs for the TFTs. This solution was an "option" that was not necessary for the project, and this way I could regain a little pride of not compromising my original idea too much. Still I had included the iPad as PFD, NG and EICAS so I had added a secondary computer to the setup and thereby I could not meet the criteria of my original idea, however I found it to be necessary and I could not find a different solution without investing a lot of money. After I had mounted the iPad and the new location of the TFTs and MFDs to the setup, I started drawing a new connection diagram to support and to give me an overview - drawing the complete connection setup did bring me a good overview but also scared me a bit, because now I could actually see how complex this project turned out to be. On the other hand it also made me quite proud because this showed me that I was able to create all of this. Conclusion I had an amazing time building this rather complex home cockpit, and I discovered that even though I am not a computer wizard or an engineer I was still able to finish this project. I of course had a lot of lessons learned throughout the project, but I am certain that I would not be scared to dive into a similar project again. It does take an incredible amount of time doing such a project, but for me it was just as much fun to build the home cockpit as it is using it afterwards. One thing that I believe is very important if you start a project like this, is to prioritize your time and concentrate on what is important in your life; hereby I mean that if you are a family person, don't forget your family! In my case family always come first, then health, then the professional job that puts food on the table and first then hobbies, fun, etc. I am very fortunate that I have a daughter (3 1/2 years old) that is extremely interested in my hobby, simply because it features a huge number of things (switches, etc.) that can move, and she really likes to go to my "office" and play. Quality time yes? I also found that setting up some simple goals was a great way of keeping me going. Building or going through a project with a long time schedule like this, did at times seem to be too much and I found myself just wanted to tear the project apart and say "that was it - that was a too big and complex project for me" but simply by setting small goals such as creating the top panels for one of the consoles or figuring out a way to support the TFTs gave me the sense of success and that boosted my confidence and gave me more energy and devotion for sure. I have already thought about potential upgrades to the setup such as building a shell or mounting a B737 overhead but to be honest that will probably not happen - I have now finished the project and the next step I think will be to take the home cockpit apart, and start all over with a new design or a new project. One thing is for sure - the TV is not the best solution for a display. Even though it is a 42" plasma, the resolution is not high enough (my TV does not have HD resolution), so a future solution will certainly be to add an HD projector providing a full 120" screen instead. I would like to take this opportunity to thank all the people that have been a part of this project - either as a sponsor, a contact or just an advisor. I am very fortunate to have all of you in my network and I really appreciate your help greatly! I would also like to thank www.Flightsim.com and www.DanSim.dk for publishing this article which I hope could encourage other people to enter the flightsim community or even to start other projects to add to the realism of the flightsim idea. Ray Andersen Rays Aviation Additional Pictures -
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Interview With Matthew Sheil What created your passion for wanting to be a pilot and when did it start? It all started when I went on my first flight in a plane when I was about ten years old. It was a DC-9 with TAA (Trans Australian Airlines) and I was travelling from Sydney to Brisbane to visit my grandparents, and from that day on I was hooked. I learned to fly as soon as I turned sixteen, which was twelve months before I could legally drive a car! A little while later, I flew my parents from Sydney to Hobart in Tasmania. This was in a twin engined Piper Seminole. I was aged sixteen years and nine months when I did this and when we arrived at Hobart, I was (because of my age) still not allowed to drive the hire car! At wood working class at school, I built a Cessna 152 simulator panel. This was with a fully working horizon indicator that was linked to the control columns. Nothing else worked, but I was extremely proud of it. Because of my love of aviation, I was forever getting into trouble in class, mainly because I spent most of my time reading aviation magazines. As you can see, I was completely hooked back then, and, quite a few years later, I am still just as hooked! Currently I own a real Beechcraft Baron B58 that I fly for my business all over Australia. When did you decide to build your own home simulator? Since day one, I have always had a passion for aircraft simulators. I love the interaction the user has with the computer and how it (the computer) manages to trick your senses into believing that you are actually flying for real. Fifteen years ago I sold an earlier aircraft I owned (a Beech Duke), so as to fund certain business projects, and because of this sale I felt lost, as I didn't have an aircraft to fly. Having nothing to fly was not something I was used to, so I thought about building my very own simulator. At about the same time, Aerowinx PS1 747-400 was in testing and due to be released, so I starting planning the construction to work around this software. The planning phase for the simulator was just over a year, and went down to the finest detail. The simulator I had planned was always going to have motion and because of this feature everything had to be of a certain strength so as to withstand the abuse caused by the motion of the simulator. How long have you been running your home built simulator? The simulator was originally started way back in 1998 and is still an on-going project. Was it originally intended for public flight training? My simulator was never intended for public flight training, but we do however offer rides in the simulator which are great fun and help with donations to the Royal Flying Doctors of Australia. Is the flight simulator FAA certified? No, it is not certified at all and never will be. Once I certify it and start offering it as a commercial operation, it is no longer a hobby but a job. I already have a job that pays me well. What software do you use to run the simulator? The main software on the simulator is currently PS1 747-400 from Aerowinx. Behind that are forty-two programs running on fourteen computers. Rather than using high powered computers for these tasks, I use many low powered computers to do them as the tasks are relatively simple. For example each CDU has its own computer. We also run utility computers that feed weather, audio, motion and EPIC controllers. Some of the computers in my current setup are still running Windows 98 as PS1 was a DOS based program. Over the years we have collected many spare computers that are pre-configured for easy swap out replacement if needed. We also run a few high end computers for feeding the visual generation software, which is currently FS2004. This is run through a Matrox card and to three projectors giving us a real one hundred and sixty degree wrap-around visual system. As we are a full motion simulator this visual system and its projectors all have to move with the simulator and withstand the abuse associated with this. What advice would you give people wanting to create their own Boeing 747-400 in their home? Unlike when I started fifteen years ago, you can now buy a lot of the equipment needed, aftermarket. When I began building my simulator I had to be creative and build most of the things I needed. I was however lucky to buy the following items which would have been impossible to make by hand: control columns, rudder pedals, seats, steering tillers, throttles, flaps and spoiler assemblies from an old TWA 747-100 classic which was being converted to look like a 400. The rest of the cockpit was all made by hand and used materials such as steel, alloys and plastics. We also used a product called Fourex for the cockpit walls, which is a product that can be shaped and then painted to give the exact feeling and appearance of a real aircraft. The advice I would give to any new sim builder, is to do your homework first. Spend the first six to twelve months just planning and researching the project! Know what you want to achieve before you start, it makes a huge difference. If you don't do the planning and research, you will find yourself changing direction during the project, and that costs money, lots of it. A final point to remember, is to create the simulator from the beginning so that you can fly it. Even if it's not complete, you have to enjoy the journey. I get more enjoyment interfacing hardware and getting something simple working than I do actually flying the simulator. Where did you find the parts needed to build the simulator? I was very lucky being one of the first sim builders around in the late 90's as many people were intrigued with my project and wanted to help. I was also lucky to find a TWA 747 being scrapped in Tucson, Arizona and was offered the chance to spend three days removing all the items I needed from this aircraft. Back then most items were just crushed and sold as scrap, but now you have to pay good money for them as they have seen an increase in demand for these items and cockpits. I was also lucky to get the plans of a Link Singer 747-400 simulator frame and this is what we used to construct my cockpit framework. My simulator was built in stages and was created in the following order: base floor section, cockpit framework, instructors station; forward panel section, pedestal, overhead, first visual system, motion, and lastly, the second visual system. I still have my list somewhere that reflects the above process, but like I said before, lots of planning helps! What are your favorite companies for obtaining parts? I guess the leader in aftermarket supplies of panels and equipment would be Peter Cos from Flight deck Solutions: www.flightdecksolutions.com Peter and I go way back, even before he started making panels, as he was trying to build his own simulator, which was an A320 (I think). It's wonderful to see that he has successfully made a great business from his hobby. Peter also designed the logo of the 747 on my web page; this was back in 1998. Unfortunately, I don't think he ever finished his own sim though. Is the running and maintenance of your simulator a full time occupation? I built the simulator to last, but I did mess up on some aspects of the design though and have had to change certain things over the years. For example the motor and gearbox on the auto throttles had to be replaced and changed five times before I finally worked out why. The failures were due to heavy handed operation of the throttles, which had the effect of stripping the gears out of the gearbox. The solution for this was to install a slip clutch assembly of a car, and so far this has worked flawlessly. Mostly it's just general day to day maintenance such as lubrication and software/computer maintenance. Most things (luckily) just seem to keep working! What are your plans for the future? (Are you going to improve on what you've already made, expand, etc). I purchased a real 1997 747-400 cockpit about twelve months ago so this will be the next phase of my project and will replace my current motion simulator over the next couple of years. It will also include real aircraft panels interfaced to PSX, which is the latest offering from Aerowinx. PSX is a fully operational 747-400 simulator that is like no other public simulator software to date and is due out very soon. What do your friends and family think to the simulator? I have many friends who come and fly the simulator. Some come for flight training, whilst others come just to enjoy the experience of flying in the simulator. Once a year we do a Round the World flight called WorldFlight: www.worldflight.com.au This runs for seven days straight and for twenty-four hours a day on the VATSIM network. During the flight we fly the simulator to forty-five airports around the world with a crew of fifteen pilots on a roster and this year will be our twelfth year running! Over these twelve years, we have raised over $250,000 for the Royal Flying Doctors of Australia. It is a great event with teams from both Australia and the rest of the world taking part. We get up to one hundred aircraft flying online with us for the week on average and last year we had forty-five aircraft at a time arriving and departing airports during WorldFlight. There are currently ten full size simulators that fly all legs of WorldFlight and we also have a Facebook page: www.facebook.com/WorldFlight ...where anyone can connect during WorldFlight; so come along and join in the fun! It starts the first Sunday of every November (Sydney time) and runs for a full week, so you can come and go as you please during the event. I have met so many people, from all over the world because of this event, some of whom will be friends for life. There are many 'home cockpits' out there, how come yours is so well known? I think it's mainly down to the fact that I was an early adopter of home cockpit building. When I started, there weren't many similar projects around, so I think this helped. Having the simulator entered into the Guinness Book of Records Gamers Edition also gained publicity. The simulator also featured in the Popular Science magazine and went viral with Slashdot, almost shutting down my internet provider's server at the time. We have had many magazine and TV news articles over the years and the simulator has been used in a few commercials and crash investigation type shows. I try and shy away from the media these days. Can we come and fly it? When I am not doing upgrades to the simulator we welcome people to come and fly for a donation to the Royal Flying Doctors of Australia, which through us, we donate 100% of any money we raise. In this way, it kind of gives the hobby a purpose and an excuse. Matthew Sheil http://www.hyway.com.au/747/747.html -
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How To...Build The Cessna 172 Cockpit Simulator Project By Rory Gillies (20 January 2004) Introduction As an avid flight simulation enthusiast for many years I've accumulated thousands of hours in the virtual skies, mostly in single engine GA aircraft such as the Cessna 172. As with many hobbies and pastimes, as your interest develops the complexity and quality of the equipment you use gradually increases. My knowledge of computers and networks enabled me to literally expand Microsoft Flight Simulator (originally 98, then 2000 and 2002, and soon 2004) using Luciano Napolitano's excellent WidevieW software (developers website; FlightSim.Com review by myself). Along with more WidevieW PC's an additional video card was added to my flying PC to move the panel from the main screen to a separate flat screen monitor, but the quest for more realism continued. Here's how my simulator has grown over the last few years: My system with FS2000 My system with FS2002 More screens and a TFT for the panel It can never be too real - how it looks today The range of hardware available to MSFS users has never been better, with a whole host of specialised, high quality commercial products on the market to enhance the simulation experience. Along with the very neat GoFlight (http://www.goflightinc.com) avionics and switch modules, I had been keeping a close eye on The Real Cockpit (http://www.therealcockpit.com) range of training devices. Unfortunately, even their Basic Training Device was well out of my price range. Recently an off-shoot of The Real Cockpit, SimKits (http://www.simkits.com), was formed, providing a full set of C172 instruments in kit form (also now supplied as ready built units). This opened up the option of building a complete cockpit simulator to augment my WidevieW system. With a budget of around £1,000.00 GBP (approximately $1672 USD) I set out to build a fully functional 172 panel complete with avionics and all switches, effectively making the keyboard and mouse redundant during all stages of flight. This article documents the project, and hopefully may inspire some of you to try something similar! Planning The SimKits range now contains every gauge you need for a full IFR 172SP panel. They also supply a panel and case, but as I was on a limited budget I decided to build my own panel from plywood. The savings made here enabled me to purchase three GoFlight modules for avionics and switches: the GF-P8 and GF-45PM for avionics and the GF-T8 switch module. As the panel had to integrate with my existing set up building it from scratch would make this easier. With the intention of spreading the cost over several months, I initially ordered just the ASI, Attitude and Altimeter gauges along with the central control unit from SimKits. I sourced the HS322 servos from a UK company, Helicopters Online for £8.81 including VAT. Some gauges require the servos to be modified for continuous rotation. These can be bought pre-modified from SimKits, or you can download instructions from the website and modify them yourself - I chose the latter route. Construction Of The Panel SimKits provide an AutoCAD drawing for the panel, which I had printed to 1:1 scale. I purchased a half sheet of 4mm ply and cut it to size, using the drawing as a template: The instrument panel cut to size The large instruments are 79mm diameter. and the small ones are 56mm. After accurately marking out the gauge positions it was off to my local tool store to pick up the hole saws. Unfortunately, these sizes were not stocked by any tool shop locally, so they had to be ordered. With the holes cut, the panel was really starting to take shape. Instrument cut-outs drilled with 56mm and 79mm hole saws To obtain a good finish the plywood was coated with a plastic film and shrunk on with a hair dryer. The whole thing was then sprayed with a matt grey acrylic paint (designed for vinyl and car bumpers). The final bit of work with the panel was to build the avionics stack, designed initially for the GF-45 and GF-P8, but with room for two GF-166 radio modules and another GF-P8 pushbutton module that could be added at a later date. The panel complete with avionics stack Construction Of The Gauges I decided to build the Airspeed Indicator first as this was a simple kit with a single normal servo and only consisted of nine parts. The kits are very well made with clear and concise instructions. The ASI took only ten minutes to put together, and once I had dug out an old AT power supply I hooked up the CCU (Central Control Unit) and calibrated the instrument. No problems there, so it was on to the Attitude Indicator, with 22 different components and two servos. The Attitude Indicator during assembly The gauge was again simple to make, taking about 1½ hours to complete and calibrate. I left the Altimeter until last, as it was the most complex kit with a plethora of gear wheels, soldering and a servo to modify. This instrument took over two hours in total, but when completed the gauge refused to calibrate. The SimKits website has a very active technical forum which is a great source of help and information, and the SimKits support department is very quick to help out. I eventually traced the problem to the servo I modified. This involves cutting the top of the potentiometer shaft inside the servo and then gluing it centrally. As there was a lot of grease inside the servo mechanism the glue had not stuck, and a tiny shard of plastic on the output shaft was turning the pot shaft when the servo ran. Clearing out the grease and gluing properly cured the problem. The first three instruments completed Three gauges and the avionics stack installed in the panel The next consignment of instruments arrived from Simkits enabling me to nearly complete the panel -- VOR 1 and 2 gauges would be installed at a later date. I had very few problems building any of the remaining gauges, although I managed to break the bulb on the turn coordinator! This gauge really needs a person with three hands to position the front plate, as very accurate alignment is required to ensure the slip ball fits exactly over the eccentric shaft. One other issue was slipping of the heading bug on the Heading Indicator. A quick visit to the SimKits forum found a solution, and highlighted that you should never glue the units face plate on until it is fully tested. Although the face plates can be removed, the noises the plastic makes when breaking the glue weld is very disconcerting! Installation And Testing With the panel largely complete, modifications to the simulator mounting unit were required to fit it properly. I had decided not to modify the CH yoke at this time, as there is a possibility SimKits may release a yoke compatible with their CCU (Central Control Unit). As the attitude and direction indicators had to be central with the yoke, the avionics panel would sit out to the right hand side. To accommodate this, the Wideview monitors had to be offset to one side, with the added advantage of creating a more "left hand seat" feel to the cockpit view. The panel in place (without IFR instruments). Note the slight offset of the monitors to the right creating a "left hand seat" impression The main and avionics panels were mounted to a wooden frame constructed over the existing yoke, fixed with small self tapping screws. I played around with the eyepoint, and with the panel assembly sitting directly above the yoke the forward view and instrument height were almost identical to a real 172. The CCU was mounted directly behind the panel giving easy access to all the connectors. With the GoFlight GF-45 and P-8 (push button unit to control the GF-45) modules installed in the avionics stack I now had a capable VFR panel. Although some mouse and keyboard actions were still required -- typically at start up and shut down -- the feeling was much closer to sitting in a real aircraft. To complete the panel the two VOR instruments plus another GoFlight GF-P8 and a GF-166 Versatile Radio Panel were ordered. The GF-T8 toggle switch unit was installed to the left of the yoke to operate most of the electrical equipment. IFR Fit The GF-166 and P-8 units were ordered from Canada at a considerable saving, even including import tax and shipping, and I was fortunate to receive a $35.00 (US) discount on the two VOR gauges from SimKits. The servos were again ordered from Helicopters Online in Farnborough, and most of the kit arrived about the same time. The VOR gauges were easy to build, although the VOR 1 gauge was a bit fiddly positioning the top plate so the needles engaged on the servo eccentrics. There was also a problem that developed with the OBS gear wheel slightly fouling the casing, which resulted in the gear shaft on the cap shearing -- the OBS turned fine clockwise but anti-clockwise seemed very stiff. As luck would have it there was an extra gearwheel cap included in the kit -- the only duplicate part I'd ever received! The bezels of the two VOR gauges were painted with silver enamel, and the black anodise was sanded off the rim of the aluminium OBS knobs to reflect the look of the real instrument. Once tested and calibrated the VOR gauges were installed in the panel, along with the GF-166 radio panel and associated GF-P8 to control the functions (more on this later). I moved the clock/timer unit (a UWIN multi-function clock/stopwatch) from the position of VOR 1 to the correct location above the engine instruments. I hadn't done this before as it would not fit into the smaller instrument recess, and a special mounting had to be made for it. The GF-45 in the avionics stack was moved down, with the radio installed below the top GF-P8. The completed IFR fit. Note the GF-T8 switch unit to the left of the yoke and the repositioned clock Panel And Avionics Layout The main panel instrument layout is exactly as you would find in a real 172SP (or the FS2002 panel for that matter). With the avionics panel I tried to create a realistic arrangement, mounting the GF-P8 push button unit above the GF-166 radio that it controls. The second GF-P8 sits above and controls the GF-45, along with autopilot functions. The GoFlight GF-P8 push button modules allow you to assign various functions to the GF-166 radio and GF-45 device. The top buttons assign Com 1; Com 2; Nav 1 and Nav 2 to the GF-166 along with DME 1 and 2 to the GF-45. The remaining two buttons are currently used for the magneto positions, allowing me to start the engine without using the keyboard. The lower GF-P8 assigns Transponder, ADF, AP Settings and Instrument Settings to the GF-45. The remaining four buttons control Autopilot Master; Altitude Hold; Heading Hold and Nav 1 Hold functions. The buttons on the GF-166 control active/standby frequency toggle plus NAV 1 & 2 Ident. The cockpit layout and aircraft controls As well as the control surfaces, the CH three-lever yoke operates the throttle and mixture, flaps, trim and parking brake. The centre lever (normally used for prop pitch) is not used at the moment. To the left of the yoke is the Main Switch Panel, a GoFlight GF-T8 toggle switch module. As there was not enough room to mount it below the main panel (it sits where the circuit breakers should be) I had to make a mounting for it: it could not be mounted flush into the panel due to the support frame behind. From left to right: Alternator Master; Battery Master; Avionics Master; Landing Lights; Taxi Lights; Nav Lights; Beacon/Strobe Lights; Pitot Heat. The alternator and battery master switches will be replaced by more appropriate switches at a later date. The avionics stack Key: GF-P8 assigns Com and Nav functions to GF-166 and DME to GF-45 .GF-166 Versatile Radio Panel. Controlled by the GF-P8 above this device acts as Com 1, Com 2, Nav 1 and Nav 2. .GF-P8 assigns ADF, XPDR, AP and INST functions to the GF-45, along with autopilot master switch and functions. .GF-45 via GF-P8 above acts as ADF, XPDR, AP and DME 1 & 2 (via top GF-P8) IPAQ Pocket PC running Memory Map Navigator software. This moving map display uses CAA digitised 1:250,000 and 1:500,000 aeronautical charts with GPS data supplied from FS2002 using Pete Dowson's GPSOut utility. WidevieW System During the construction of the panel I carried out some upgrade work on the WidevieW system, building a new server and making the front view a client. This enabled me to reduce the work the server had to do by not displaying high resolution and quality graphics -- all the sliders were set at minimum and FS was run in a 640x480 window. Schematic diagram of the entire system. Note how the server no longer displays an outside view. The current WidevieW system comprises a 3.1GHz P4 with 1GB DDR RAM running Windows XP Professional. The five clients are mostly 2100XP Athlon units with 512MB DDR RAM and GeForce 4 Ti4800 graphics driving 19" Iiyama screens. The clients all run Windows ME. Each computer is equipped with a Fast Ethernet NIC connecting to a 16 port unmanaged Fast Ethernet switch. TCP/IP is used for file sharing, and WidevieW runs on the IPX protocol. Not shown in the above diagram is the file server, not actually integral with the WidevieW system. This holds a complete copy of all the add-on scenery and scenery config in a shared folder: any additions to the scenery library is added here first then copied to all the WidevieW PCs via a mapped drive. This ensures all the computers in the system have an identical scenery library and layering -- very important to ensure identical views. There is also now an Instructors Station that connects to the flying PC via FS2002 multiplayer. Connected to the server (or flying PC) via USB is the TRC Central Control Unit, the GoFlight avionics and the CH Yoke and Pedals. All the GoFlight units are connected into a high power USB hub, with the controls and TRC CCU plugged directly into the PC's ports. The iPAQ is connected via a 115200 bps serial link into COMM 1. Operation And Flying As the system has evolved, so has the complexity of operation. As the startup and shutdown sequences have to be performed in a specific order I have created a simple checklist for the purpose. From cold it takes around 10 to 15 minutes to make the system flyable. The startup and shutdown sequence checklist A typical flight proceeds as follows. Firstly the master power switch is set on providing power to the entire system. The monitors are then switched on (if they are left on there is quite a power surge when the master switch is turned on). I then check that the LED on the TRC Central Control Unit is steady red -- if the LED is flashing the unit still has an active configuration which can prevent the instruments working correctly when the link to FS is started. I then check all the USB connections are secure for the GoFlight units. After the initial checks each computer is switched on, and TRC CCU power supply is turned on. FS is then started on each PC (six of them!) and the weather is set on the server. After setting the time the default flight is started on each PC (normally saved from the previous flight), and as all my flying takes place within the area covered by the Visual Flight/GetMapping VFR scenery volumes it can take several minutes for the flight to load. Once the flight has loaded on the server I start the TRC Link software that links the CCU with FS, via FSUIPC. As the panel boots, each client has to be set to WidevieW client mode with blocking mode (WidevieW Config). If the computers are left as clients at the end of the previous flight it can take over 10 minutes just to load the flight in the VFGM VFR scenery areas, and sometimes they can get stuck in a loop and not start at all. After the clients are set the altimeter correction has to be adjusted on the TRC Link software -- the altimeter does not auto zero, and may be one or two thousand feet out at startup, although it is always complete thousands. The sub base unit under the seat is switched on, and finally WidevieW is started on the server. This loads the current server weather on the clients and synchronises the time. At last it's time to go fly! Once "in" the aircraft -- always the RealAir Simulations 172 re-registered G-JHML -- it's time to pre-flight and fire up the engine. After checking the parking brake is set the battery master is switched on followed by the beacon. When the aircraft is fitted with a working fuel selector I will switch the fuel on at this point, but for now the fuel is left on "both" at all times. The throttle is opened ½ an inch, mixture full rich, and after a virtual "Clear Prop" I advance the magnetos until the engine fires into life. Checking the oil pressure, I set the RPM at around 1100 for the warm up then flick on the alternator and avionics master switches. The radios and selector buttons are then all checked and set, clock set, altimeter subscale set, DI synched with the compass, and after another check of the T's and P's it's time to move to the engine run up area. The airfield I usually fly from is Eddsfield, a small grass strip in East Yorkshire. As I can be pretty sure there's no other traffic about I usually do the run up at the threshold, a short distance from the parking area. Setting the parking brake the RPM is gradually brought up to 1900, and then the magnetos are checked: first the right on its own, then the left, looking for about a 50 rpm drop (it never really varies from 50 rpm but it's good practice for the real thing!). The throttle is then retarded fully for the idle check before setting at 1100 rpm again. The final cockpit checks are made (trim, flaps, fuel, mixture full rich, T's & P's), landing lights on and a virtual blind call on the Eddsfield frequency to announce "Golf-Mike Lima ready for take off runway two-seven, right hand circuit to full stop landing" and we're away. The parking brake's released, and counting to three the throttle is advanced to fully open. Keeping straight with the rudder and holding the weight off the nose wheel with some back pressure on the yoke we soon reach 55 Kts on the downhill runway, and the aircraft gently un-sticks. Holding off just above the strip I let the speed increase to 75 Kts before climbing out over the fence. The after take off checks are completed (flaps, throttle full, mixture full rich, airspeed, T's & P's) and the aircraft is trimmed for around 75 to 80 Kts, switching off the landing lights at 500' AAL and turning right for the crosswind leg. The climb continues to 1000' AAL where we level out, reduce power, turn downwind and trim. A quick scan of the engine instruments to check the T's & P's, the throttle and trim is adjusted to maintain around 90 Kts, and a downwind call is made when abeam the 09 threshold. As we pass the 27 threshold I reduce speed to 80 Kts and re-trim, before turning base when the threshold is about the eight o'clock position. At this point the first stage of flaps is dropped and the aircraft re-trimmed, then the landing checks are completed -- fuel, altimeter, DI, mixture full rich, T's & P's, brakes off and landing lights on -- and the base call is made. By this time the speed has dropped back to about 70 Kts with the first stage of flaps, and a slight reduction of the throttle pitches the nose down to commence the descent. At about 700' AAL the turn to final is commenced, lining up with the runway at about 550' AAL and dropping the next stage of flap. I trim the aircraft for 65 Kts and call "Golf-Mike Lima final Eddsfield two-seven". If the wind is light I may drop the last stage of flap at about 300' AAL and re-trim. The throttle is hardly touched during descent unless large corrections in the approach path are required. Airspeed is controlled by pitch, and once trimmed the aircraft will almost fly itself right down to the threshold. As we approach the threshold I ease the nose up slightly aiming for around 60 Kts over the fence. The flair is initiated, and the aircraft held a few feet off the runway until the airspeed decays (this is easy with the peripheral vision from the side views). Just as the stall warning sounds the aircraft lightly settles onto the runway, and I keep the nose wheel off the grass and gently ease it down as the speed reduces. Once all three wheels are on the ground the aircraft comes to a stop with little or no braking required. As there's no taxiway at Eddsfield I turn to backtrack the runway, running through the after landing checks -- flaps up, transponder standby, landing lights off and taxi lights on -- on the way. At the parking area the parking brake is set, RPM set at 1000 to cool the engine, avionics master off, mixture idle cut-off to shut down the engine then turn off the magnetos. Once shut down the beacon, alternator and battery master switches are turned off and the flight is complete. As you can see from the above the realism of the system is absorbing, and you feel like you are actually flying. With the peripheral vision the feeling of motion is quite surprising -- some people who have flown the system for the first time have actually felt slightly nauseous! You pay far more attention to real instruments than those displayed on a screen, and because most of the systems are in place you tend to follow accurate procedures. It's not the sort of setup you can jump into for a quick flight as there is so much preparation, and as a training aid for real world flying I personally find it invaluable. With the recent addition of an Instructors Station to my setup it's now possible to simulate system failures and in-flight emergencies such as engine failure, greatly enhancing the training potential of the system. Once the flying is over the system needs to be shut down correctly following the checklist. The most important thing is to reset the clients to server mode, otherwise the next session can take a very long time to start. Further Developments As the sim developed and became more realistic in operation and appearance, any distractions in the surrounding room became more are more noticable, detracting from the feeling of flying. These included seeing through the slight gap between the monitors, the ceiling light, chairs and other general objects. By covering the sim just above the monitors with a sheet of MDF and taping all the gaps up with duct tape I managed to exclude most, although it became very dark! The addition of a 6W fluorescent light illuminated the panel and controls without too many reflections. The result of this was true "total immersion", with the feeling of motion much more prevalent. With the room darkened there are no distractions at all, and it is very easy to forget you are sitting in a spare room in the house! The MDF "roof" in place and the gaps between the monitors covered up with tape. Notice the 6W fluorescent light at the top right Most Recent Changes Work continues on the project even as this article awaited its turn to appear online. I took the plunge and modified the yoke, along with the installation of the lower panel and throttle/mixture controls (which need new knobs). Incidentally the battery/alternator master switch is from a 172! The yoke was modified using 22mm chromed tube. The results are shown in the photos below: The Future As with all projects like this it's never really finished! I'm very happy with the system as it is at the moment, but improvements could be made in areas such as trim and flap control, pedals, throttle and mixture, magneto and starter switch... the list just goes on! My current wish-list includes the SimKits RS372 Radio Stack which is a very faithful reproduction of the stack you would find in a new Skyhawk. At the time of writing the unit was still not available, although pre-orders were being taken (including mine!). I have also recently ordered the Davtron digital clock and warning panel which will complete the main panel instrument fit. The tape and roof are temporary additions until I re-design the entire simulator mounting. I plan to make it a fully enclosed unit with a door entry, no wires, keyboards or mice in sight, and an additional seat for an observer. At this point the trusty CH pedals that have been with me so long will probably go, and I will rebuild the panel in modular form like the real aircraft. The only thing that puts me off doing this now is with the sheer pleasure I'm currently having flying it I couldn't bear the downtime! The Instructors Station has enabled even greater realism with the prospect of failures and weather situations completely out with the pilots control, although the failures are limited to specific systems. With products such as Alert! Pro appearing offering a far greater range of in-flight emergencies and scenarios I'm looking to integrate such a program with the simulator via Pete Dowson's WideFS, giving the Instructor a much greater range of emergencies to throw at the unsuspecting pilot! It is actually great fun sitting in the instructors' seat and watching the pilot's expression when you cut the engine just after take-off, then ask him why he didn't use the full length of the runway! Development of WidevieW is progressing, and to keep up with new features the inevitable switch to FS2004 will eventually happen as any further developments for FS2002 cease. On a system such as this upgrading to a new sim version cannot be taken lightly, and compatibility issues can become a real headache. For the moment anyway I intend to stick with FS2002, and when the time is right to upgrade I'll document the project - watch this space! Acknowledgements: This article was originally published over at Flightsim. No, the home of "Cockpit" and the WidevieW forum. Thanks to all the help I've received with this project from the members of the Flightsimnetwork Cockpit Builders, WidevieW and SimKits forums - it's truly appreciated. Rory Gillies rory@shetland.flyer.co.uk -
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How To...Build Your Own Home Cockpit By Mike Smith The time had come. After 6 long years of playing Microsoft Flight Simulator at my desk, using a slow computer and a joystick, I was now ready for the ultimate flight simming experience. Building my own cockpit. Oh, I had kicked the idea around many times but never really had the motivation to actually do it.... until now. It was to be the greatest of all home cockpits ever built. (At least in my mind!) When I finished, I didn't want people to think I had lost my mind. I wanted them to be absolutely certain of it. To them, it was just a silly computer game. To me though, it was my escape to the skies when I couldn't really fly for real. (After building this thing, I'm so broke; I may never be able to fly a real plane again.) As a certificated private pilot, I can only wish for those every other day flights to far away places in my rented Cessna 172. It is a real treat if I get to go up once a month just to stay comfortable in the air. The rest of the time, it's Microsoft Flight Simulator to the rescue. I rave to anyone who will listen about how invaluable MSFS has been to me in obtaining my pilot certificate. The realism of the controls, the real world weather, interactive air traffic control, and the realistic scenery make this a program that goes beyond the "gaming" level. It truly helps real pilots stay proficient when they can't really be in a real plane. I lost track along time ago, but I must have 400 hours using MSFS and I am certain I am a better pilot because of it. Anyway, back to the home cockpit. I spent months plotting and planning every detail of this project. By the time I was actually ready to begin construction, I had already "built" this thing in my mind about five different ways. The planning definitely paid off when it came time to put it together. Think about where you will put this thing since it will invariably wind up quite large when you are finished. Mine wound up being @ 4'W x 6'L x 6'H. I have no idea how much it weighs, but it's fairly heavy. I decided on the basement since it would be the most out of the way place and I wasn't about to give up my parking spot in the garage. (Weeks of begging wouldn't convince my wife to give up hers either.) My biggest problem now is that this thing was built in the basement and is never coming out. It would have to be carefully disassembled and I hope that won't be necessary anytime soon. With the cockpit now usable I can honestly say that even though I was an avid flight simmer before, this has taken the experience to a much higher level. More comfort, more realistic controls with the use of rudder pedals, bigger display. Now it really is "as real as it gets". In the pages that follow I will try to document the entire process I followed while planning and building my cockpit. I hope that you decide to take the plunge too. It really was a lot of fun. Just to see the look on peoples faces when they see it, especially other pilots, it was worth every minute. Search the web sites I have listed, ask pilots for suggestions until you find the design that fits your needs and budget. Just remember; It's your dream, make it as big as you want! I broke the entire process down into three phases: planning, design, and construction. Phase One: Planning How far do you want to go? How much money do you have to blow on this thing? Single seat or two? Build your own seats or get them from a car? What kind of display? (I would have loved a 46" Plasma Screen TV/monitor but a national search for a rich uncle yielded no results, so I opted for the 20") These are all good questions that will have to be answered before you can begin. Personally, I told myself right up front that if I was going to do this, I wanted to see peoples jaw drop when they saw it. Obviously, I also had to make it as realistic as I could afford to. Here is a listing of the final product and the approximate costs: Feature Cost Materials (Lumber, hardware, paint, etc.) $325.00 Seats/Seatbelts FREE Switches, electronics 50.00 Used aviation intercom, 2 headsets 200.00 Computer 475.00 Used 20" monitor 175.00 5 pc. speaker system w/ subwoofer 35.00 Mini USB keyboard 45.00 Handheld trackball mouse 25.00 Yoke and Rudder Pedals 265.00 Cup holders 10.00 Certificate holder (don't want to get busted on a FAR!) 3.00 Map pockets 20.00 Moldings, door edge guard 20.00 Printing (warning labels, graphics, etc. 25.00 Total $1673.00* *Plus one other incidental that was needed since I built this in the basement. A dehumidifier, which set me back $150.00. As you can see, even though I kept it fairly simple with instrumentation and gadgets the cost can get up there very quickly! Keep in mind; I started acquiring these things months ahead of time so the cost was split up over the course of several months. Sources like eBay proved to be invaluable when trying to locate items like a real external PTT microphone like you'll find on a rear plane, and used headsets. They can usually be had at a pretty cheap price too. Otherwise, your local home improvement store, auto supply store, and Radio Shack can supply you with everything else you will need to build your masterpiece. Phase Two: Design Obviously, I wanted something that would look like an airplane but wouldn't take up the entire basement. I searched the web sites and got some ideas and then started sketching my own designs until I found a good alternative. I wanted a two seater with a "hooded" area for the monitor to focus all visual attention on the monitor. I also decided against anything fully enclosed, too hot inside during the summer months and I sure as hell wasn't going to add the air conditioning option. Instead I opted for the "hooded" area which I made using black fabric (a black bed sheet purchased at a local department store), which can also be pulled tight over the entire top enclosing you in a realistic night environment which makes for some pretty cool night flights. The end result wound up being sort of a fastback design which looks very cool. The panel design I went with was very simple. I couldn't afford to outfit it with real instruments and gadgets but couldn't resist adding the ignition key lock and master switch. I also made my own labels with the usual warnings found in the real cockpit. Seat and panel placement was done using the actual measurements from a Cessna 172 I fly regularly. The seat height, panel height, distance to yoke, etc. are all true to the original. I have already had several comments from people about how "real" it feels while sitting in the pilot seat. I think so too. One thing you won't find anywhere is a set of plans to build one of these. I looked everywhere! Unless you want to spend $50,000.00 or something on a manufactured simulator, you're on your own. Once you have a visual idea of what you want and some drawings, you start making everything from scratch. Not to fear though. With a little creativity and hard work you'll have a simulator you can show off with pride. The most important thing to remember is plan, plan, plan. As mentioned earlier, you will practically have it built in your mind before you ever start construction. Phase Three: Construction The construction phase had several segments and I tried to list them in the order I actually completed them: * Preparing the seats and seatbelts Lucky for me, I am in the car business so finding seats and seatbelts was easy. The main thing to remember is that the seat width can't be more than @ 22". Space is pretty limited so seats out of an old Buick Roadmaster just ain't gonna fit. I used a pair of reclining bucket seats from an old Mazda Protégé that fit perfect. I think any compact size car would work. If you have no connections in the car business you can always try picking up an old junker in the classifieds or try the salvage yards. Once you find them, their gonna need a good scrubbing first. Before After Whatever seats you find you will have to be modifying them on the bottom so they will sit flat. The rails are normally all different shapes to fit the contour of the cars floor where they bolt in so this will take some work but it's not that difficult with a hacksaw and lots of muscle. The seatbelts took some real creativity. I needed something that pulled from between the two seats like a real Cessna. The post had to be mounted and braced so it would not loosen after repeated use of the seatbelts. A 4X4 porch post proved the perfect start. (See what I mean about getting creative!) Anchoring the top of the belt Anchoring the retractors The finished product The rest is pretty self explanatory in the photos but since every seatbelt will be a little different, you'll have to come up with a slightly different design. Good Luck! * Building the platform base/installing the seats The platform was a piece of cake. Just a basic 48" X 72" rectangle with evenly spaced studs in the center. 3/8" Wafer board was used on the top and the bottom making it more than strong enough to hold the weight of everything. I added heavy duty wheels to the bottom also in case I needed to move it around the basement. I also thought if I got really bored my wife could push me around to practice taxi instructions. (For some reason she didn't see the humor in that!?) Anyway, once the platform is built just use cheap flooring adhesive and cover it with your gray carpeting. I mounted the seats on top of pieces of 4X4 which gave me the perfect height based on my actual Cessna 172 measurements. (see diagram #1) Your placement depends on your actual size and the fact that you want to be able to slide the seat forward and back. This takes a few tries before doing the final anchoring but you'll get the right fit. Once the seats are anchored you can then mount and brace the seatbelt pillar in the rear center of the platform. * Framing the monitor shelf Framing of the monitor shelf is pretty simple. Just use 2X3's to form three rectangles with one being anchored at each outboard edge and the final one centered. (see diagram #2) Once they are completed just install a piece of the 3/8" wafer board as a shelf and use your adhesive and carpeting again to cover the shelf. * Building and installing the "foot" area and instrument panel The panel was simple, just use 1X3 to make an outer frame and then a piece of luan plywood for the panel itself and attach to the top of the three monitor shelf studs. The foot hole board was cut from the 3/8" wafer board according to diagram #3. The panel board is painted gray while the foot hole board is carpeted. Be sure to paint any exposed wood surfaces with black paint before you proceed with the next step. Otherwise, you'll need a chiropractor to straighten you out after you have to crawl inside the belly of this thing to paint it. * Exterior panel construction, painting the interior The exterior panels were cut from Luan plywood using a simple saber saw. After a few measurements to figure out the angles and curves you're ready to cut. I actually used an old round serving tray to cut the curved areas where you step in. (Hey, that's all I could find.) Mark everything out on your 4X8 sheet of luan then cut away as soon as you're happy with the look of things. The left and right sides are the time consuming parts. The front and back are just straight cuts. After your finished cutting, get the gray paint out again. You'll need to coat all the interior sides with a couple good coats and let them dry before you can proceed. Don't worry about the exterior sides for now. Well get to that later. * Framing the "hood" and installation Framing the hood was just a matter of building two identical side pieces (see diagram #4) that anchor to the top of the monitor shelf. The fabric is then stapled over the top of these pieces and they also serve as another anchoring point for the front panel. Again, paint the side pieces black and let them dry before you tack the fabric on. * Painting and detailing the exterior, striping, etc. I went around the entire exterior edge with basic door edge guard from the local auto supply store. One roll did the trick. This turned out to be a nice touch and will keep the slivers to a minimum. I painted the exterior with three coats of gloss white and true to the Cessna Skyhawk SP, I used the blue, gray, and yellow striping colors found on newer 2001 models. Striping was done using my eyeball and a roll of masking tape. Having nothing to go by except a picture from the internet the striping took awhile but looked awesome when it was done. The N-number is done professionally in vinyl lettering. I went with the number of the plane I passed my private pilot check ride in. It seemed the obvious choice. A few quick measurements to insure both sides would be even and sticking it on was a breeze. For the final touch a couple of US flags on the tail and that was it, perfect. There were few other little touches I had to add. The real scanner antenna on the back, the phony plate, etc. Why not...we live once! * Wiring it all up Wiring will vary based on what you decide to put in your cockpit. I chose to install an AC cord through the side panel that went to the keyed ignition switch and then through the master switch. The two switches, when on, supplied power to the two power strips inside the belly where everything would plug in. I encountered two problems though. First, after hours of wiring up the two switches my son came to the basement (His mother probably sent him down to make sure I wasn't going to blow up the house.) and immediately saw the cool ignition lock with the key. He grabbed hold of it to turn it and got shocked. Of course he was barefoot on the damp concrete floor while I had been sitting in the cockpit the whole time I was working on it so I never got zapped. After calming him down and convincing him his mother needed to know nothing about this little "incident", I disconnected the metal ignition switch and will leave it there for show. Secondly, the very first time I had some people over to "unveil" the flight simulator, a pilot friend of mine was in the middle of the flight when he looked down and said "hey look, this thing even has a real master....." click. Well, I'm not sure what happened but after he killed the power to everything by turning the switch off, it took an hour and a half and a full reinstall of the game make it work again. Anyway, that switch is now disconnected as well. Basically I have two cool looking switches that don't have any functional purpose anymore. I now have everything safely wired and grounded so no one needs to worry about getting shocked. Next came the sound. No problem there, just hooked my audio switch to the computer sound card, plugged the speaker system into one side of the audio switch and the intercom system into the other. Now, with the push of a button you can have booming external sound or put the headsets on and talk to your passenger while all the game sound gets piped through the headsets as well. The sound thing was a little confusing to rig up. I actually had all the components about a month before I started building and hooked it all up to figure out how it worked so there would be no surprises later on. * Constructing the center console The center console is crucial for realism. Other pilots instinctively reach down for the trim wheel before they realize there really isn't one there. To give you an idea on difficulty building the console, it took me one day to build the platform, the monitor shelf and foot hole. The console took me three days to build, install the intercom and mount in the cockpit. All the graphics and labels were created right on my PC and printed out with a color laser printer. (Courtesy of Kinko's) I carefully trimmed them out and stuck them on using ordinary lamination sheets. It worked great and the visual effect "suspends disbelief". * Installing the yoke and rudder pedals For budget reasons I opted to start with a single yoke and rudder pedals. Due to the control wheel shaft that goes through the yoke I had to install it directly into the panel. I used great patience and time measuring for this cut. Remember, we are now working on the finished product and a screw up here means re-doing a whole lotta stuff. Nonetheless, the yoke installed flawlessly and I used another item from the auto supply store to finish the edges, wheel trim molding. The pedals just sit on the floor. I installed a block of 1 X 3 in back of them so they can't slide anywhere while being used. One little flaw was the fact that once the yoke was installed It was off center by @ 1 1/2" to the left. This may not sound like a lot but trying to fly this way was very uncomfortable. So, there goes another Sunday. Both the seats came back out and I moved them both the proper distance to the outboard edge to fix the problem. Thank god I had the space to work with; it would have driven me insane to look at it like this. * Computer selection and setup Computers, what can I say. When they work we love em'. When they don't, well you know. Deciding on the right computer for this project was easy. Get the best. I worked too hard up till now to use some old computer or skimp on a new one and hate the way everything worked. Having said that, my plan was to get enough computer to make this thing work great today with every display setting maxed out and have enough for when the next version of MSFS comes out so all I'll have to do is install the discs and keep right on flying. So, I scoured the classifieds for weeks waiting and finally, there it was. This is what I wound up with: Athlon 1300 processor 512 MB RAM 64 MB GeForce 2Video 20 GB Hard Drive 52X CD ROM USB 10/100 Ethernet Card Windows XP Home Edition It works great, smooth, great scenery. The goal was to stay ahead of the curve as best I could afford and I think that has been achieved. Other computer details to consider: Windows XP & USB: A must have. With Windows XP I don't think there is a device invented that this wont detect and install automatically. No drivers to fool around with, stuff just works as soon as you plug it in. This was especially important to me since I was using a USB Keyboard, USB Mouse, the yoke and the rudder pedals all hooked into a cheap $15.00 4 port USB hub. No bother though, I turned the computer on and plugged in the hub and that was it. Anti Virus Software: Another must have. I don't know about you but I download a lot of aircraft, panels, etc from the internet and I sure would hate to lose it all because somebody gets into my computer. Back Up Files: I always keep a backup folder with all my aircraft, gauges, and flights in it. In the event the game crashes and you need to do a reinstall it takes just a few minutes to get yourself right back where you left off. Well worth taking a few minutes to do this. Broadband Connection: If you don't have it, get it. Downloading real world weather or an aircraft online takes seconds instead of hours. Worth every dime. Well folks, that's about it. There are dozens of other details and comments I could share but let's do this instead. Email me at msmith31@twcny.rr.com with your comments, questions, suggestions, or criticism. I truly had a great time building this thing and I know you would too. I'm not sure I'll ever really be finished. My future plans include: adding inter-connected yokes and rudder pedals, and adding a multiple monitor video card. I'm sure I'll be the first in line for Flight Simulator 2022 when it comes out so I hope this thing lasts. Until then, think big and go for it. The skies the limit! (I have also added my very own instructor station which utilizes the software on the professional edition.) Mike Smith msmith31@twcny.rr.com Disclaimer: The information provided in this article is to be used at your own risk. I make no claim of fitness for any product, service, website or endorse any manufacturer, company, product, or web site. Use all proper precautions when using power tools and don't drink and fly.
