We’re still working!

For all of you that have been watching this blog over the weeks, don’t dispair (OK, so you weren’t going to actually DISPAIR), we’re working and havn’t had time to update things recently.  A small interruption in construction had to be endured as pseudo-spring comes to us here in Northern Michigan, but some personal issues aside, we’re still very much underway with the project.  We’re going to construct our computers soon, and begin the testing and burning in process….along with that, we’re almost done designing the ATC station, and are working on the logistics of the shell of the sim.

Won’t be long, we’re going to post some stuff soon…

MT

Finally, the progress pictures

Here are the pictures that you have been waiting so breathlessly for. The pictures show the Progress that we have made in creating the MIP and MIP Support, as well as the assembled pedestal. The pictures also depict, more or less, the stages in which the components were completed.  Our plans call for us now to turn our attention to installing electronics shelving in the MIP support, and then to begin to build the computers that will power the main functions of the sim….on the premise that we’ll need some displays in order to properly measure and cut the appropriale holes for LCD screens in the MIP.

As always, click on the picture for a larger view.

Well, that’s it for this entry, sports fans! Leave us some comments!!!!!! We’d like to know how you think we’re doing, and feel free to comment and criticize….(be nice).

We’ll talk to you soon!

Mark and Tom – - – Your benevolent hosts.

More Pics to Come

Sorry about the delay in uploading more pics….bit of an interlude, but never fear…work goes on. We’ve fabricated the support structure for the MIP, and have created OSB support beams to solidify the desklike arrangement. We also have created the “shelf” assemblies for the support structure, and obtained bracket hardware to strengthen the entire structure.

We discovered some 1/4″ MDF at our Home Despot that we will be using to fabricate the backing for the MIP.  The MDF was labled hardboard panels, but it’s 2′x4′, and we’re happy with it.  I worked up the appropriate curve for the edges of the panel utilizing Photoshop CS and the ellipse tool to create the original shape, then converted the original elliptical selection to a path for minor tweaks.  Subsequently, I filled the shape with black on a white background, printed it to actual size with my Canon i9900 on 13″x19″ paper, and laid it out on our MDF panels.  It fit perfectly!  We’ll make and finesse the cut this weekend.

I am finalizing the order for Angle Steel, and will be ordering several hundred feet. The MIP Support will be finished this weekend, and the angle steel layout and design will be finalized. In the mean time, the basement will be readied for that phase of construction.

Pictures in the morning, folks!

Mark

Cockpit Shell Skeleton

We spent a lot of Saturday working out the details of the fabrication of the cockpit shell, and we have decided to go with painted 12 and 14 gauge angle steel (see this example: 737 Project | Construction diary ). We plan to obtain this locally, but if we cannot, we will order the materials from the following source (this source is also noted in the blogroll): Angle Steel

Mark

Support Structure

Layout of the support structure is complete, with the bulk of the assembly being made of 1/2″MDF. Once the basic construction is complete, a template for the MIP will be constructed, as well as the MIP Subpanel template. The actual panel will most likely be made from 1/8″to 1/4″masonite, with instrument bezel overlays in either ABS or another equally malleable plastic. I do plan to attempt some sort of backlighting, so ABS may not be the best choice…however, I will only simulate the original backlighting for the 45, so not much will be needed. Backlighting will most probably be provided via cold-cathode lights running from an AT power supply.

Construction continued on Saturday, with the standards of the MIP support structure being completed. We also completed the lower MIP Backing (a 72.5″long 6.3″wide piece of 1/2″MDF). Next we will complete the monitor and electronics support structure and braces for stability. Here’s a picture of the 4 support pieces:

You’ll note the forward pedestal section in the lower right hand (and all of the MDF dust on the puzzlemat floor!) Canting the lower MIP panel at 15 degrees provides better access to and visualization of the switch positions.

More soon!

Mark

More Preliminary Work

Today, the prelim work consisted of a trip to Home Depot (HD from now on) to grab a sheet of 3/8″ plywood.  I had the HD guy chop this into 2 3′x3′ pieces (with leftovers) and brought it home, along with some florescent lighting for the simpit work area.  The Plywood will be used to extend the table surface of my Dremel router table in preparation for using it to create radio panels and such things.

My idea for the gear handle is to create a prototype of clay, then make a plastic resin mold of this prototype and cast the handle.  Plastic resin can be drilled, and it should not be difficult to cast it in an opalescent white color, utilizing some filler.

Next, I’ll be fabricating the Pedestal, utilizing measured drawings that I’ve developed from detailed scale measurements  of stock photos.

Note that I’ve added two links in Builder Resources for access to OSS versions of Network Design  programs.  These are available for Windows and Linux, and seem to work fairly well.  I was looking for an open source version of  MS Visio, and I think Dia will be it.
Later!

Mark

First Steps

This weekend the first real steps in the construction of the structural components of the sim took place. A number of full size sheets of MDF and OSB were placed in the basement (1/2″ MDF and 1 sheet of 3/4″ MDF, and 3/4″ OSB), as well as 2 full 1/8″ masonite sheets and lots of 1×2. Some of the MDF had gotten a bit of water on the edge in the garage, and so the edges were trimmed to prevent capillary action from ruining the board. I was not aware of the amount of DUST that MDF creates when cut with a circular saw, but beware, it is a GREAT DEAL.

Anyway, getting the dust up and planning out the initial construction of the pedestal (1/2″ MDF with plastic inlay top) and the initial drawings for the Main Panel template.

Thanks for ALL the help, Tom!

More later.

Mark

Interior Cockpit Lining (Curved interior shell)

I have hit on the idea of using closed cell PVC foam (Sintra FoamBoard) to create the curved surfaces for the interior lear cockpit. The foam is reasonably inexpensive for the amount I need, can be bought in bulk or piecemeal, and can be thermoformed into curved shapes. I have included a link in Builder Resources for a good internet source for the board.

The Plastic Center

Well, I visited the plastic center here today, and WOW, they are really helpful, interested and excited about working the Lear project! They have CNC capability, and very reasonable prices. They carry Acrylic Mirror, Sintra in many colors, and ABS, Plexiglas, Polycarbonate, and many and varied plastic tools (jigsaw blades, plastic drill bits, electric bending heating strips, glues, polishes), and all manner of plastic scrap can be had for about 2 bucks a pound. I’m now going to be involved in making templates for the finished pieces that I’d like to fabricate. From ABS or perhaps white translucent Sintra I’m going to do the full Main Panel, complete with edge bezels for the EICAS and PFDs, as well as the MFD and the Primus 1000 radio control heads. I’ll be doing the glarescreen header panels in the same type of plastic, and will give them a coat of special grey plastic paint to accurately match the Lear grey. The folks can even CNC and laser cut the labels for K1 and other switches that I’ll need. Saves me the cost of a CNC setup (for now anyway).

For the Pedestal, I’ve decided to create the TOP level out of ABS plastic, and the rest of 1/2″ MDF. Heavy, but lighter with the top section of ABS. For some areas, I’ll cut aperatures, for my Go Flight Control modules I’ll surface mount them with screws or bolts. Hopefully I’ll be able to house at least one computer within the pedestal, although that idea may change as things develop.

Home Depot here carries 1/2″ 4×8 MDF Board, and Lowes seems to carry the same product. I would rather use 1/4 inch because of the weight involved, but I think 1/2″ will do.

The base of the simulator will probably be built on some form of plywood, or perhaps MDF, although I think plywood (marine grade) would be more stable. I also need to build the mounting for the Main Panel, but that will be done after the pedestal is constructed. From micrometric analysis of the cocpit visuals, it apears that the Lear 45 pedestal is sized at 70% throttleward reduction, meaning that the main portion of the pedestal is 30% wider than the throttle quadrant forward. I will size this pedestal proportionally to the installed components, i.e. the CDU (Flight Deck Solutions CRJ version) and the Go-flight modules (which are 7.5″ wide).

Enough for now, great information and tutorials at the FDS site, and I’m looking forward to getting going! The first pictures will be posted soon, basically detailing the empty basement in which the Lear is to be fabricated.

Mark