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  1. #1
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    Aerosim Solutions B737 simulator rebuild

    Hi all
    Since the arrival of two beautiful Flight Management Computers from FDS on Christmas Eve, I have launched back into the rebuild of my simulator. I thought it might be a good idea to start a thread on it's revival as a few builders might want to follow the project as it unfolds. I will be using many of the products I offer for sale and it will be a chance to see how they are utilized. My sim has been stripped back to it's bare steel frame so I am more or less starting from scratch.
    The first job was fitting new seat brackets to the framework, the seats will be 30mm higher than before and 75mm wider apart to allow for a bigger centre console. The next job was fitting the new control columns as seen here - http://www.youtube.com/watch?v=exL6H4yP8xc

    Next on the agenda is a new set of rudder pedals and I've decided to make a set to save a few bucks, I'll post progress pics as the rebuild unfolds.
    01-Footrest-sides.jpg
    02-Footrest-carcas.jpg
    03-Footrests-ready.jpg
    04-Making-footplate.jpg
    05-First-prototype.jpg
    Looks the part hey? More soon on the rebuild and as always feel free to copy!

    Cheers Gwyn
    www.aerosimsolutions.com.au

    737NG using Prosim737, Immersive Calibration Pro, Aerosim Solutions motorized TQ & cockpit hardware, CP Flight MCP & FDS SYS1X, SYS2X & SYS4X, FDS PRO FMCs, AFDS units & Glarewings, Matrix Orbital ELEC display, Pokeys Landing & Cruise alt display, Buttkicker Gamers, 3 x BenqMW811ST projectors with a Matrox Th2Go
    http://www.aerosimsolutions.com.au
    Supporter of MyCockpit.org, please join me in donating!!!

  2. Thanks Hessel Oosten, choffmann thanked for this post
  3. #2
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    Re: Aerosim Solutions B737 simulator rebuild

    Hey Gwyn,

    Very, very nice idea for making the pedals. Wonderfull.


    Regards, Wendy
    Last edited by Westozy; 01-31-2011 at 09:12 PM.

  4. #3
    150+ Forum Groupie Tony Hill's Avatar
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    Re: Aerosim Solutions B737 simulator rebuild

    Nice one, looking forward to seeing her revamped and in the flesh...
    "Tony"

    In memory of Flt Lt Tony Hill who, on 5 December 1941, at the request of Doctor R V Jones, successfully photographed a small "Würzburg radar" at Bruneval on the French coast. This from a height of only 200 ft, at high speed, under fire and from a camera mounted obliquely behind the cockpit.

  5. #4
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    Re: Aerosim Solutions B737 simulator rebuild

    Nice, Gwyn

    I'm using some PVC myself and just wonder if you have tested the strength - I mean how hard can you push the pedal without the foot-plate leaving the slots in the side support (I expect you have slotted in the plate) or do you have any support on the backside.
    In a B767 I believe they talk about 60 lbs and a desperate pilot can push even harder as the end of
    the runway getting too close too fast….

    Just curious - thanks for sharing and for sure this will be something to copy.
    Regards,
    Per-Erik
    www.hoddo.net

  6. #5
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    Re: Aerosim Solutions B737 simulator rebuild

    Quote Originally Posted by Perik View Post
    Nice, Gwyn

    I'm using some PVC myself and just wonder if you have tested the strength - I mean how hard can you push the pedal without the foot-plate leaving the slots in the side support (I expect you have slotted in the plate) or do you have any support on the backside.
    In a B767 I believe they talk about 60 lbs and a desperate pilot can push even harder as the end of
    the runway getting too close too fast….


    Just curious - thanks for sharing and for sure this will be something to copy.
    Hi Perik, you have guessed how I did it! The pedal plate sits about 8mm back from the edge of the hoop section and I have glued some fillet pieces in place at the sides and up at the toe end. I use industrial strength cyanoacrylate glue on PVC which is just as strong as a PVC weld. BTW, PVC is quite easy to weld with the right welding sticks and a hot air gun. I'll post a pic of the rear of the pedal soon.
    The main load will be on the grip with the grooves and this is basically a 50mm solid block drilled to 1/2" and it will pivot on a 1/2" stainless steel axle. The toe brake movement will only be rotating a potentiometer and the pedal is certainly strong enough, the PVC is heavier than it's aluminium counterpart!
    I'm not sure about offering these as an Aerosim product, they take about two hours each to produce so sourcing real pedals still seems a better option at the moment to be honest! I have completed my rudder mechanism design and I will share it with our membership as the build progresses and I have new photos to display...
    Anyhow, got to dash, getting married in 2hrs 7minutes, (dedication or what?)
    Cheers Gwyn
    Last edited by Westozy; 01-28-2011 at 10:23 PM.

    737NG using Prosim737, Immersive Calibration Pro, Aerosim Solutions motorized TQ & cockpit hardware, CP Flight MCP & FDS SYS1X, SYS2X & SYS4X, FDS PRO FMCs, AFDS units & Glarewings, Matrix Orbital ELEC display, Pokeys Landing & Cruise alt display, Buttkicker Gamers, 3 x BenqMW811ST projectors with a Matrox Th2Go
    http://www.aerosimsolutions.com.au
    Supporter of MyCockpit.org, please join me in donating!!!

  7. #6
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    Re: Aerosim Solutions B737 simulator rebuild

    Well, .. Congratulations on the Marriage

  8. #7
    75+ Posting Member Polmer's Avatar
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    Re: Aerosim Solutions B737 simulator rebuild

    Wow... Love the footpedals!
    Great job on those babies.

    Polmer
    ~Polmer
    Level-D 767, Opencockpits+ SIOC+ Lekseecon

  9. #8
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    Re: Aerosim Solutions B737 simulator rebuild

    Quote Originally Posted by Westozy View Post
    Anyhow, got to dash, getting married in 2hrs 7minutes, (dedication or what?)
    Cheers Gwyn
    Wow, Gwyn, astounding -

    my heartfelt congratulations to you and the bride. Thinking about you both makes me feel good....

    I do sincerely hope you will be thinking about a honeymoon in Thailand

    Sent you some mails a while ago that went unanswered, am I on your spam-list ?
    Erhard in Thailand

  10. #9
    25+ Posting Member 737dragon's Avatar
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    Re: Aerosim Solutions B737 simulator rebuild

    I like your work..thx

  11. #10
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    Re: Aerosim Solutions B737 simulator rebuild

    Thanks guys, here's some more pics of the rudders being built...

    Tool for forming the rudder hoops

    A warmed up hoop is 'stretched' into shape

    A hoop ready for assembly

    The hollow axle glued into place

    Underside showing the fillet braces and the footplate that has been glued in and wrapped around the axle using a heat gun. The 6mm thick PVC becomes very flexible when it is heated up.

    Four sets completed

    Four sets of pedals and footrests

    I'll be starting the mechanical components of the rudders next!

    Cheers Gwyn
    Last edited by Westozy; 01-31-2011 at 12:58 AM.

    737NG using Prosim737, Immersive Calibration Pro, Aerosim Solutions motorized TQ & cockpit hardware, CP Flight MCP & FDS SYS1X, SYS2X & SYS4X, FDS PRO FMCs, AFDS units & Glarewings, Matrix Orbital ELEC display, Pokeys Landing & Cruise alt display, Buttkicker Gamers, 3 x BenqMW811ST projectors with a Matrox Th2Go
    http://www.aerosimsolutions.com.au
    Supporter of MyCockpit.org, please join me in donating!!!

  12. Thanks Perik thanked for this post
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