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fsaviator
03-25-2009, 09:07 PM
After "many" years of development, my GNS 530 is complete (almost)... Just waiting on the front panel to arrive. Unfortunately, I will be gone for a couple of months so I won't be home when it arrives. In the interest of time, I'm posting what I have. I'll update the post when I get the panel installed.

Many thanks to Tuomas and countless others for the inspiration, help and ideas

I've attached a write up and price list.

Here's the pics.. Click on them for a larger photo

The first attempt. Using the Protoboard turned out to be more trouble than it was worth.
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0001.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0002.jpg

The switches, Pots and encoders
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0003.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0004.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0005.jpg

The LCD
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0006.jpg

The ExpressPCB I had made, Front and back
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0007.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0008.jpg

The case with the Desktop Aviator 2040 and 2090 boards
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0009.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0010.jpg

Wiring It up
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0011.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0012.jpg

Starting to look like something...
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0014.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0015.jpg

The LCD Controller is now installed
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0016.jpg

Coming together...
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0017.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0019.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0021.jpg

Sweet! No, working with aluminum is not my strong point!
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0023.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0024.jpg

Now it looks like something... really wish I had ordered the front panel
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0026.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0027.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0028.jpg

Pics of the various screens... all the knobs and buttons work!
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0029.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0030.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0031.jpg

http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0033.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0036.jpg
http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/th_DSC_0038.jpg

http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/P1010365.jpg

http://i274.photobucket.com/albums/jj267/wsoeldner/Cherokee%20235%20Sim/P1010359.jpg

TOTAL COST... $580!!!


Warren

Bob Reed
03-25-2009, 09:40 PM
WOW!!!!! wsoeldner (http://www.mycockpit.org/forums/member.php?u=5052) Thank you so much for this. Looks great!!

Michael Carter
03-25-2009, 10:45 PM
That is absolutely the Cats ***!

Well done. When does production start? ;)

fsaviator
03-25-2009, 10:53 PM
Thanks guys!

I'm enjoying this thing so much, even without the panel installed (and knobs), that I'm actually thinking of redesigning the board to fix the shortcomings...

The funny thing is, once you have the parts, it's fairly easy to put together. Production would be a fairly easy process!

Thanks again for the kind words...

You know guys... your avatars are making me jealous... I've been flying the PMDG 737NG while away from home, and now that my GA Cherokee is done... I'm itching to start on a big iron simpit (don't tell my wife!).

Warren

Michael Carter
03-25-2009, 11:11 PM
I can't get over how well that turned out. I'm amazed. I wish you'd have posted this before I wrote my article on scratchbuilding. I would have done an entire paragraph just on your GPS.

Fantastic work!

If you ever build another, Mouser sells the standard sheet metal punches for your cut outs.

colt45
03-26-2009, 10:20 AM
Very impressive final product even without the front panel. That will undoubtedly finish it off when it arrives.

Just last night I was pondering how to get mine started in terms of fastening my PSOne screen to a mdf "panel" I will be cutting out. Mine will not be as "high fidelity" as yours but with any luck should function nonetheless. Will be sure to reference your write up and this post as I progress.

Well done.

dnoize
03-26-2009, 04:22 PM
What a great build !!

Well done !!!

Stef

fsaviator
03-26-2009, 05:18 PM
Thanks colt45, Stef....

Stef, My little GA is nowhere in the class of your 737 :( but I believe I stopped at your site a couple of times for hints and stuff over the years.

This forum is a great resource for cockpit builders, even if I get the same feeling as being number 10 for take-off in a Piper GA, at a large airport. Boxed in by Heavies!!! :lol:

Thanks again!

Warren

dnoize
03-26-2009, 05:47 PM
I should update my site one day. I havent been working on it for 2 years i think and my home sim has progressed by far since then.

But...... i started a little c172 sim on the side recently....i missed those VFR flight....and dont tell anyone...but im starting to like the GA more and more :-)

So your tutorial on the GNS350 was much appreciated !!

stef


.

wannabeaflyer
03-27-2009, 04:02 AM
WOW WOW And More WOW thats an absoloutly great project you have shown here, just my way of saying thanks for sharing the info, its clear that a serious amount of care and attention to detail was involved and shows what can be done .... i have not yet had a chance to read through the PDF you attached to this post so please ignore my request if the answer is found in there ,when i read through it later, one question ? i have open cockpits interface cards and a Hagstrom KE72 encoder card looking at the reality XP site i got the impression that the GPS functions were Mouse click activated and did not initially see a list of Keypad /button Press options may i ask how you got over this issue or am i looking at the wrong places for the info. can easily see myself buying the software as i already have the hard ware inc PS0ne monitor but need confirmation before placing the order, i know i should send this request to RealityXP but as i was here i just thought i'd ask someone that has actually compleated this type of project Cheers :-)

fsaviator
03-27-2009, 12:21 PM
wannabeaflyer,

Thanks for the comments!

You should have no issues with the Hagstrom and open cockpits IO cards. I haven't used either of them, but I know the capabilities of the Hagstrom. Great cards. If I remember right the Opencockpit IO is pretty much the same. either can be used in my setup. I chose the Desktop Aviator cards because of the rotary encoders. The DA Model 2090 seemed to be very easy to setup. I'm sure there are other options out there.

As for the RXP GNS 530, I'm using the 2005 non-WAAS version (haven't upgraded yet), so I can't speak for the WAAS version if that is what you have, but I would imagine that it's the same setup. Of all the instruments I have put into my simpit, this was the easiest!

The RXP 530 has an ini file that allows you to set keyboard commands for all it's functions. In fact, it allows you to use any combo of keys which is good. For instance, I'm using CTRL+F13-F23 and SHIFT+F13-F23 etc. Those commands are not used for any FS commands so it's easy to deconflict.

You then map the commands in FSUIPC to the buttons. This was the hardest part, as my keyboard doesn't have F13 etc, so I couldn't use the FSUIPC built in keyboard command mapping page. I had to manually do it in the FSUIPC ini file. Not hard to do, and Pete Dawson's manual is excellent and walks you through it.

So, a rundown on how I did it:

1. Your buttons/encoders etc connect to an interface card (Hagstrom, OC, whatever).
2. Your interface card connects to the computer (USB, serial, gameport, whatever).
3. Your interface may or may not require software, but will show up as a game controller in Windows, or as a conroller in it's specific software.
4. At this point, start FS, go into FSUIPC, and using the options, set each button press or click to a key command.
5. Finally, go into the RXP 530 ini file and set the commands to correspond to the key command.
6. Your done!

There are posts in the the RXP forum that explain how to remove the border from the GNS so that only the map is visible.

There are posts in the RXP forum that explain how to edit the 530 ini file and it's location.

Hope this helps, and feel free to ask me if you need anything else,

Cheers

Warren

AndyT
03-27-2009, 04:42 PM
Top quality work! Keep it up. You have inspiried many others by sharing your passion. :D

wannabeaflyer
03-27-2009, 05:19 PM
Hi Warren big big thanks for taking the time to answer my questions , you sir are a start ;-) thanks to seeing your Project i am now going to place an order for the Reality XP GPS Module.. i am at present putting the finishing touches to MY DIY Mini CNC router and the plan is to make my Panels and PCB on this machine, Am learnig as i go but your design will give me a focus point still have to work out getting my PCB designs to G code but have some great info and hopefully some time soon will be able to Post some picture of the router and the Radio Panels and something like your GPS unit... on behalf of all the wannamake one o those :-) out there thanks you once more for showing the way ... i will finish this motion cockpit by hook or by crook and it will look all the better thanks to the modules. to say its goona be a hybrid is an understatement but hey thats the fun of it :-0

fsaviator
05-31-2009, 12:35 PM
OK,

I have returned home temporarily. I am headed out on vacation with the family next week, but will be back the middle of June to finish this up.

I received the Front Panel while I was gone, and it fits perfect! I've also ordered the rub-on decal paper that I hope will work to label the buttons and knobs.

I hope to have updated pics by the third week of June. I plan to upload a video to Youtube as well.

Thanks to all for your emails and kind words.

Warren

fweinrebe
06-01-2009, 03:05 PM
Great build!!

Tell me the GPS software is it a FSX/FS2004 gauge or a stand alone program?

warvet
06-02-2009, 01:56 PM
Warren,
You are a true master craftsman absolutely fantabulous job. Does the $580 include everything including the faceplate? Can it be hooked up to phidgets 16/16 Cards?
Again my friend you out did yourself do you have any vids of it in operation id love to see it.
Tim

Buddym
06-03-2009, 09:44 AM
There seems to be quite a bit of interest in this project, so I wanted to get some input... I am almost finished with the hardware portion of my GPS 500, the screen, front panel, buttons etc. I will post some pics in a few days.

At first I considered connecting it via the standard cards we all use like IOcards, Bodnar, etc. The past couple of days I have been thinking of using a connection method like USB or ethernet. While it would at about $40 to the cost of building the unit, it would make connecting it easier and more flexible, IMHO. A small software app would handle getting the button-presses from the GPS buttons and send the required keypresses to the GPS inside FS. This way the GPS could be connected to switch, hub, or any pc in the sim network that had FS or wideclient running. (I think)

My question is this: if you were going to build a GPS and had to pick a connection method, would you choose USB, ethernet, or even serial port, or would you use what you have already?

BuddyM

fweinrebe
06-03-2009, 05:48 PM
My question is this: if you were going to build a GPS and had to pick a connection method, would you choose USB, ethernet, or even serial port, or would you use what you have already?


My opinion is that USB to be used. Ethernet's complexity and cost are a dislike, Serial ports is probably the easiest but it is getting harder to get PC's with serial ports. Usb is not that hard nowadays and every PC comes out with many USB ports. And USB hubs easily extends it with more available plugs.

fsaviator
06-04-2009, 12:49 AM
I like your idea of using Ethernet... unfortunately, my software design skills are nil. I went with USB because of the ease of use, but I could definitely see the advantages with ethernet.

Looking forward to your pics!

Warren

fsaviator
06-04-2009, 12:52 AM
The software I'm using is the RealityXP GNS 530 (pre-WAAS version). I'm using it with FS9, but I believe the new version, that is WAAS enabled is FSX compatible. I haven't tried my version under FSX.

I finally have the perfect machine that runs FS9 without issues under Win XP SP2. Everything works, and I actually get to "fly" instead of troubleshoot, so... I'm holding off upgrading my FS machine with Vista and FSX.

Warren

Buddym
06-04-2009, 10:10 AM
Is the USB method you use your own design?

BuddyM

fsaviator
06-05-2009, 01:45 AM
Is the USB method you use your own design?

BuddyM
No, I'm using USB cards from Desktop Aviator. Real simple to install and they don't require proprietary software

fsaviator
07-06-2009, 09:58 PM
And now..... (drum roll)....

It's really finished:-D

I played around with different labeling options for the faceplate, to include rub-on transfers, but nothing looked as good as my trusty labeler.

The whole GPS is mounted into the avionics stack, which luckily I built removable from the beginning. Made it easy to pop it in. I ordered the faceplate to fill the hole completely. In fact, if you look at the upper part of the faceplate, you can see that it looks like a small panel hole cover, but it's actually part of the faceplate.

The only thing I didn't think through was how to mount the faceplate. I ended up JB welding a couple of brackets to it and mounting it directly to the GNS530. It's now one self contained unit. In fact, you can see the tape in a couple of photos that I used to hold it in place while the JB weld cured.

Anyway, tested it out on Vatsim last night and offline today. Shot all sorts of GPS and ILS approaches into Denver and Pueblo, and flew all over. Every feature works just like the GNS530 in my RW plane.

This thing is a dream to use. What a difference having knobs and buttons to twist and push than a keyboard. In fact... I don't use a keyboard at all now. There are only six keyboard commands I need (Reset DG, Altimeter Set, TrackIR on, TrackIR center, PDF Kneeboard, and FSNav). If you look at the pictures that show the fuse panel, you'll see that I put six buttons in the fuse panel for those commands just in case I need them. I fly online most of the time, with charts, so I really don't use the commands, but they are nice to have.

In one of the pics you can see my very old laptop that I use to run FSInn for Vatsim Comms, and in another you can see the head of a microphone that I use when I'm tired of wearing a headset.

So... 'nuff said, here's the pics:

http://i274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/th_P1010356.jpg (http://s274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/?action=view&current=P1010356.jpg) http://i274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/th_P1010359.jpg (http://s274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/?action=view&current=P1010359.jpg) http://i274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/th_P1010361.jpg (http://s274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/?action=view&current=P1010361.jpg)

http://i274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/th_P1010362.jpg (http://s274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/?action=view&current=P1010362.jpg) http://i274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/th_P1010365.jpg (http://s274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/?action=view&current=P1010365.jpg) http://i274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/th_P1010347.jpg (http://s274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/?action=view&current=P1010347.jpg)

http://i274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/th_P1010346.jpg (http://s274.photobucket.com/albums/jj267/wsoeldner/RXP%20GNS530/?action=view&current=P1010346.jpg)

gokhotit
07-07-2009, 02:48 AM
That is BAD@$$. Anything IS truly possible.

Buddym
07-07-2009, 08:49 AM
Fantastic job! Mine is almost identical, I hope it looks and works as well as yours!


BuddyM

fweinrebe
07-07-2009, 03:14 PM
I played around with different labeling options for the faceplate, to include rub-on transfers, but nothing looked as good as my trusty labeler.

Which labeler did you use for the labels?

Nice photos of your sim !!

fsaviator
07-14-2009, 01:52 AM
It's a Brother P-Touch PT-2100 Labeler.

I use white text on clear 1/2 labels.

Thanks for the kind words. It's been a long road, mostly because I'm gone from home so much, and partly because I actually took the time to research the GPS. The Simpit's been complete for about a year and a half.... the rest of the time I just gathered parts and researched for the GPS.

fsaviator
07-14-2009, 02:05 AM
Well, I'm off again for about six months. Didn't get a chance to shoot video:sad:

So... that about wraps it up. $580 for the parts, and about $100 by the time it was all said and done on parts that didn't get used, were bought to see if they would work, and were bought and didn't work. No regrets, I learned a lot on this project.

What would I do better? I would spend a little more time thinking the PCB through. This one turned out great for a first try, but if I was to do it again, I would make better use of the capabilities the PCB brings to the table. I would also add a seperate power brick (which I have, but didn't use) and actually build the USB hub into it. that way, there would only be one USB cable, a power cable, and the monitor cable coming out of the back. Maybe the next project.... Garmin 1000??? How about it RXP?

Thanks to all for following along and commenting! I'll be monitoring if you have any questions.

Warren