First Piece of Cockpit Structure Constructed

I wasn't up to doing any "fussy" wiring type stuff....... and I am waiting for some 10K ohm slide potentiometers to arrive anyway.... so I thought I'd take a couple of hours and tackle the first item for the construction of the cockpit structure itself.

The first section I decided to build for this project is the "shelf" unit that will sit directly behind the center console structure.  All of the design work for the simulated cockpit has been worked out in a CAD program.... so all the dimensional stuff has been resolved there.  Dimensions were lifted directly from that drawing and translated to the real wood parts.

This shelf unit will hold a single "glass cockpit" video monitor at a 15 degree upward angle, will support the right side of the main panel facing tipped at a 15 degree angle, will serve as the support for the glareshield unit that will sit on top of it, and then be topped by one of the exterior display monitors.  The sizing of the various components has been designed so that the center of the exterior view display monitor lines up with my eye level when seated in the pilot's chair.

The monitor located on the middle shelf of this unit will display the engine management instruments.  There is room underneath at the floor leve l to hold two tower style PC's.

It is constructed out of two thicknesses of medium density fiberboard....... 3/4" for the two upright sides..... and 1/2" for the shelves themselves.  The span is so short that I do not think I need a brace under the center of the shelf that holds the monitors.... but if neccessary I will add a piece of 2" x 2" pine across the middle.  Small pieces of pine are used to secure the fiberboard, utilizing screws and glue on all joints.

The holes in the various sections are cut using a standard holesaw in a hand drill.  These are to be utilized as pass-throughs for any necessary wiring.

Photo #1



This shot shows the use of Elmer's Glue in addition to screws for making the structure rigid.  MD fiberboard is weird stuff.  It tends to want to "rip apart" if you put too much stress on it.  The glue helps.  The wood strips are used to allow you to screw into the face of the fiberboard...... not drill into the edges.


Photo #2



Here you can see the center monitor shelf screwed securely to the pine furring strip that has been itself screwed to the side upright piece.  Again, glue was used for all joints.  The narrow board at the botton serves to stabilize the lower rear "legs" of the shelf.  The front does not get any, since PC CPU's will get placed in here.  The center console will locate directly in front of this part too.

Photo #3



Here is one view of the completed first shelf unit.  



Photo #4




Here is a second view of the same unit.  The location of most holes for the wiring can be seen.

None of this structure will be visible from the cockpit.  It will all be hidden behind the main panel facing, the center console, and the glareshield.

So....... get out your carpentry tools and join me folks  .  About $12 USD of wood and screws and glue and 2 hours of time.


best,

................john

Thanks Will. 

I may get another couple of hours tonight to tackle starting the next cockpit section.  Next part of the cockpit itself to make is the center console.  That will be a litle more complex... but not much.

The problem is that I am trying to cram in one more VDT down there (  ) in the center console for a FMC or a radar display.  The logical place it should go puts it on the slanted part right next to where the center console butts up against the main panel facing.  But I can't put my hands on something like a 7" or 9" dirt cheap monitor right now.  I've got a small monochrome one that has a 7 3/4" x 10 1/4" screen... in a 11 1/2" x 13" "box".  But that size puts the font edge of the throttle quadrant back about 13" from the panel face.  I am thinking that is a little too far back for comfort for the right arm to conveniently reach it.

The real time consuming stuff with all of this will come when I have to do the wiring for all the switches and stuff. 

You off your night shift thing yet?

best,

....................john

Construction Started On Cockpit Center Console

I managed to steal about 3 hours last night from 10 PM to 1 AM to get started on constructing the center console portion of my simulated cockpit.  The basic construction techniques here are the same as what was done for the part that I documented in a post prior to this one in this thread.

All of the design work was done in my CAD program and I again just transfered the dimensions onto the wood.  The center console is constructed mainly out of 1/2" medium density fiberboard, with 1/8" fiberboard "whiteboard" material for the panel facings.  All of the main wood for the console came out of 1/2 of a 4' x 8' sheet.  It is screwed and glued using scrap pine furring strips.  Total cost for this part was again about $12 USD.


Photo #1


As You can see in Photo #1 above...... I spent some time playing with the monitor that I want to add in here as a FMC / TCAS radar display.  Here I am checking to make sure that the dimensions are going to match the CAD design....... because I did not leave a lot of room here for this!  The paper CAD plans are in the foreground.  The already partially built throttle quadrant was also used to help visualize if this is going to all work out OK  .

I really want to have that extra monitor in this console.  There are just too many things that you need to display in a large jet cockpit  .  This will bring the number of monitors for the "glass cockpit" part of this cockpit project to four.  It will be driven by my old Tcera laptop...... which is small and can be tucked into a nook somewhere.

The monitor I am utilizing here is one I picked up at the dump a week and a half ago.  People just throw this kind of thing out.  It is a 7 3/4" x 10 1/4" display, monochrome white, 604 x 480 vga display in perfect working condition.  The monochrome is perfect for a TCAS type display...... although I would have prefered green, not white.  "One man's junk is another man's........ "

To save space in the console I decided to strip the housing off most of the monitor.  I just left the facing portion on the monitor to serve as a "flange" to mount it in the wood construction.  If you are following this project and decide to do this also....... be vary careful with opening monitors!  They can have pretty lethal charges still in them even when unplugged.  Watch how you handle them.  And the picture tube can implode badly if you bang it on anything.



Photo #2


Photo #2 shows the two main side panels cut out.  Note the sloping upper console section.  This area takes the most planning.  The edges of the boards you use must have the same slope so that the facing fits against it correctly.  Using a skillsaw at an angle is sufficient for these cuts..... you don't NEED a tablesaw.

The two side pieces were cut out and then set "back to back" to compare the cuts.  Slight adjustment was done with a saber saw so that the two matched as well as possible.

With careful planning the "scrap" from the two side panels will make all the other pieces.



Photo #3


In photo #3 you can see the trickiest cut in the project.  This large flat sheet with the bevel cut edge is the top rear console wall.  This angled cut has to match the slope of the upper portion ofthe console.  I used the skillsaw set at an angle.  The corner braces also have to be cut at an angle to match.  You can see the "screw and glue" construction here too.



Photo #4


In photo #4 you see the rear console wall where it butts up against the main panel support structures.  This section is cut out to allow good air circulation for the FMC/TCAS monitor that will be located there.  I will also likely install some boxer fans near each monitor in the setup (with "real" cooling controls located on the overhead panel) to help keep them all cool.  The holes in the bottom serve for more wiring passthroughs.  The corner construction of the "box" is also evident here.



Photo #5



Photo #5 shows the internal structure of the console a bit.  The wall that separates the lower console from the upper part does not go all the way to the bottom.  This will allow the lower area to be utilized to store all manner of electronic stuff.  It also facilitates wiring passthrough.  The "dividing wall" will get a strip of furring along it at the level of the lower panel facing to help support that material.

This lower section will eventually get some internal dividing and supporting walls.  These will be spaced to match the electronics that will get installed there.  I already know that on the lower left... next to the pilot seat...... there will be a section set up to take a couple of Goflight radio units.  So there will be a wall set up to support them on their panel mounting width of 7 1/4".



Photo #6



In photo #6 you can see the "stripped" monitor set in place in the upper center console.  The mount is simply two furring strips screwed into the console walls at the appropriate height so that the monitor face is flush with the console face.  The console panel facing will go over this...and have a cutout for the display screen.  The monitor is "friction fit" here.... no mounting screws or anything..... it just sits on the flange created by the wood.  It's quite stable 'cause the fit is so tight all around  .  But it is easily lifted in and out for doing any work.  The two screws on the left side of the "mount" are evident on the dividing wall.  They will be covered by the throttle quadrant.



Photo #7


In photo #7 you see the center console from the rear, showing the monitor in place.  The ease of access to the monitor workings is self evident.  Also the wiring passthrough holes.  The monitor does NOT project beyond the outside of the rear wall..... so that the console will butt up flush with the other support structures for the main panel.



Photo #8


Photo # 8 shows the state of the project at this time.  The center console has had the sheets of 1/8" fiberboard "whiteboard" cut and put in place.  The hole for the monitor display in the upper panels section was cut out by drilling holes at the corners and then cutting with a sabre saw.  The throttle quadrant is just sitting on top of the lower console section at the moment.  The center console in this picture is butted up into its desired position next to the shelf unit that will hold the engine management display monitor and glaresheild (see prior posting in this thread).


So..... there you have the details about the status of my crazy "homebrew simulated cockpit" efforts so far.  There are 5 hours of labor so far into the cockpit "framing" part of this project.  Hope this documentation is inspiring someone else to "take the plunge" with this kind of thing .  Undertaking this project is an incredible amount of fun!  And I haven't even FLOWN in it yet!

More as it all develops.


best,

.....................john

quick question: exactly what cockpit are you trying to build? is it supposed to be a fighter cockpit, cessna, etc..?

This part of the construction project is now continued in the thread labeled "Cockpit Main Support Construction Part Two"..


best,

.............john

Wow J
Nice pit man. Love it.

What more can I say.

Thanks for sharing some great Ideas
Imz