I have finally started!!!!!!

[phil744]

Well, after 6 years of wanting, 2 years of planning and one month of spending today i have made the very first part of my sim!!!!!!!!:p:p:p

As you may know i have recently got my new sim room/workshop a few weeks ago and over the past few weeks been building it all up and playing with all my brand new shiny toys, and this weekend I got to the point where it was time to actually start making somthing that will go towards this insane pipe dream we all have of actually having your own full blown flight simulator!

Currently sat here typing this with a coffee and a pile of panels all illuminated perfectly, how buzzing am I at this moment.

I know it dont look much, but its a start

http://i17.photobucket.com/albums/b52/madmini1/DSCF3467.jpg
http://i17.photobucket.com/albums/b52/madmini1/DSCF3466.jpg
http://i17.photobucket.com/albums/b52/madmini1/DSCF3465.jpg
http://i17.photobucket.com/albums/b52/madmini1/DSCF3464.jpg

[autocadplease]

That's how we all started! Good luck and keep us up to date on the progress.

[Matt Olieman]

Good for you Phil!!!!! :) :)

I'm glad you've taken pictures, because you don't want to forget this moment!!!! Take pictures as you progress, so you'll never forget how you felt when you accomplished your projects.

And Thank You for sharing this moment with the rest of us :)

Matt Olieman

[phil744]

I have definitly got the bug now, its midnight here at the moment and i have work in a few hours but im now starting to re-make the radio head and starting the pass sign panel, audio panel, rudder trim and have a go at an FMC aswell!!

[warvet]

Phil,
Those look fantastic, Who made your panels for you? Your definitely on an amazing rollercoaster ride now :) Good Luck.

Tim

[phil744]

Phil,
Those look fantastic, Who made your panels for you? Your definitely on an amazing rollercoaster ride now :) Good Luck.

Tim

Ive made the panels, that what ive been doing all weekend, very rewarding.

Just had a first stab at the FMC, this is one complicated piece to figure out, a couple of more layers to cut before its complete.

http://i17.photobucket.com/albums/b52/madmini1/DSCF3468.jpg

But as usual i got carried away, i decided to make a job load of panels to try different methods of painting cutting machining and engraving, i even got some parts for the legend that is the 737 aswell!, but i dont know why, im not making a 737 but i do like its colour.

http://i17.photobucket.com/albums/b52/madmini1/DSCF3469.jpg

[Joe Cygan]

Outstanding job Phil!

This work is incredible.

[warvet]

WOW! Phil thats insane...unbelievable work my friend. How did you do the backlighting? If i wanted an overhead done in back light for A340 would ya do it? how much would it cost me?

Tim

[phil744]

WOW! Phil thats insane...unbelievable work my friend. How did you do the backlighting? If i wanted an overhead done in back light for A340 would ya do it? how much would it cost me?

Tim

Im afraid the backlighting is a closly guarded secret for now, keep in mind the EVAC and XPNDR panels only require 4 LED to illuminate, but looks OK just using three, not decided on exactly how im going to do it yet.

As for the overhead, well i know i can do the different colours, but some pieces may be too big for my machine, i will have to look into it.

[Michael Carter]

Wow, when you do it, you do it First Class.

That looks really great.

[BHawthorne]

Nice panels! It might be cool to do a how-to for panel making. I know there are a few of them out there already, but everyone does their panels a bit differently. More places to pick up info the better. :)

What sort of hardware and software are you using to make the panels? I'm assuming a cnc mini-mill of some sort? If so, what mounting method are you using and what bits do you use to etch the lettering? I'm going to be in the same boat shortly. I've got an X2 mill I'm cnc retrofitting atm.

[phil744]

Thanks for the great replys.

Yeah, im going to have to do a new thread on how panels are made, call it "a panel is born" or somthing daft like that;) i think its a facinating process.

Basically there all laser cut and laser engraved, got some sweet machinery to do them on, but all the machining is done manually on my X2, however I have bought a CNC router but it got destroyed in postage so im still waiting for that.

[marius]

Really excellent work!!! I would love to see a thread on how you did all this. 2 thumbs up

[ivar hestnes]

Very nice work Phil.

Congratulations.

:)

[PascalHaldenstein]

Congrats to your incredible work!!!:D
Looks very nice.

Regards

[Lewis Simmons]

You legend Phil! Never seen anything better!

[Joe Cygan]

You legend Phil! Never seen anything better!

Hey Phil must be nice to be legend status, maybe one day;)

[Lewis Simmons]

Ha.

Don't base it on what I say, wait for the majority. Joe, you know you are a legend! I've told you so many times;)

[Joe Cygan]

Ha.

Don't base it on what I say, wait for the majority. Joe, you know you are a legend! I've told you so many times;)

Just trying my best at being funny! Lewis you the man!

Thanks Bro.

I take my hat off to Phil, first class guy all the way.

[phil744]

Thanks for the great comment guys, im sat here at work typing this with such a grin across my face (:D < bit like that) nearly a year of trial and failure but now i got it right.

Had a bit more of a play with the backlighting and trying to figure out how to replicate fillament illumination using white LED's, looked into alsorts of wierd and wonderful combinations with no results, then i picked up a white board marke that was sat in front of me all of the time and simply dabbed the LED and it worked!!!! sorted.

I will get round to doing some sort of guide on the HI-TEC method, and also how to get decent results with just a drill, piece of metal and whatever you find lying around on the floor;)

Oh, im selling some 737 ones, i have no use for those thought someone might like em.

Again, Thanks

[Lezam]

Awesome stuff phil! Those panels look excellent!

[phil744]

Ok, a little update on this weekends fun.

Well to be honest, not a great deal, I decided it was time to attack the jumbo's overhead panel.

So i gathered all the reference material, (airliners.net entire collection of 744 cockpit pictures!;)) a few of my own pics, sketches and a pile of real parts to measure up for fitting and then started. I decided not to go into as much detail as i did with the pedistal because i would be here for ages, still got the buzz of panel producing so i just wanted the things in my hand before the end of the weekend, but i will go into more detail soon that also includes the artwork required, and if you are wondering, I am dredding doing the artwork for the electrical and fuel panel, I can imagine its going to take several attempts before geting it right, not to mention destroying my own panels, this is going to be fun!!:twisted:

I think i spent most of the time deciding what configuration I wanted my 747, bit like buying a new car and looking through the optional extras. So on some parts I reverted to the older style -400 that used more toggle switches rather than Korrys to keep it cheap. and mine is hopefully going to be based on KLM's PH-BFG (Big Fat Git:p) as in the avatar, obviously I have a soft spot for that aircraft.

So off i went and did the 3D cad work, took around 14 hours to complete and my eyes hurt afterwards, so panels started to look like this, simple:roll:
http://i17.photobucket.com/albums/b52/madmini1/1-1.jpg

Now it was time to cut some plastic, I decided that it would be a good idea to cut what will become the aluminium backplates for the panels out of 3mm acrylic, its cheaper to get it wrong now rather than have them made form aluminium and there all wrong.

So here is the complete overhead I ended up with after a gruling cad session.

http://i17.photobucket.com/albums/b52/madmini1/DSCF3591.jpg

Now its time to check everything fits, i had a pile of parts used during the CAD work and now had to go through everything again, checking things like clear Korry covers dont fowl the lightplate, bolt holes/screw holes are not to big or to small, Unfortuantly I dont have enough parts to fill the entire overhead but now i know real parts fit perfectly!

Ok, I made a few errors, but out of everything I only have to re-do 2 panels, not bad really for a first attempt.

http://i17.photobucket.com/albums/b52/madmini1/DSCF3594.jpg
http://i17.photobucket.com/albums/b52/madmini1/DSCF3597.jpg
http://i17.photobucket.com/albums/b52/madmini1/DSCF3599.jpg

[Matt Olieman]

WOW!!!! When you put your mind to it.... you JUST do it!!!! Fantastic Phil, nice work :)

[Joe Cygan]

Very cool stuff Phil!

[jmig]

That is amazing work. I am astonished how much you have done is such a short period of time.

[dodiano]

Wow! Excellent work my friend!!

Regards,

Roberto

[Tomlin]

Oh man....if I had the CNC and the laser...the damage that I could do to my finances buying acrylic! That's great work, and it's neat to see you able to do so much!

[marius]

Are those real aircraft switches and annunciators?

[phil744]

Oh man....if I had the CNC and the laser...the damage that I could do to my finances buying acrylic! That's great work, and it's neat to see you able to do so much!

Yeah, there is nothing left of my finances now, beed down the acrylic shop again, bought every they had... oops:(

And yeah, there real switches and annunciators

[phil744]

Ok, its Friday at last! time to continue with the fun, been very busy at work this week, got a new product to finish off which is allready 2 months late so am going to have to work over the weekend now:(:(:(

But every night been spending a couple of hours in my little white room with bars on the window, this weeks little task, the FMC!!! (better than work!!!!)

However, I must explain, when I left school in 1998 i started to have a go at sim building after getting hooked on FS98, things where going well until i came across the small problem of the FMC, and i know a few others were having the same issues as me at that time, so i gave it a go and failed misurably:mad:. So for the past 10 years i have had a personal hate against all forms of FMC's!! and was not looking forward to having another go at my own personal arch enemy!

I cut one set a few weeks ago and tried putting it together then gave it a quick coat of paint at the start of this week, It was OK but i still thought "come on Phil, you can do better than that" so revision 3 of the FMC was designed, cut and half an hour ago assembled for the first time,

I now think that i have won this battle, what do you think, im rather proud:D

http://i17.photobucket.com/albums/b52/madmini1/DSCF3615.jpg
http://i17.photobucket.com/albums/b52/madmini1/DSCF3617.jpg
http://i17.photobucket.com/albums/b52/madmini1/DSCF3616.jpg

[Matt Olieman]

That looks beautiful :) :) :) How did you do the beveled edging??

[Polmer]

Wow, I love your FMC!

If you ever decide to sell them, count me in as a customer.
Count me in for two!


Polmer

[Lewis Simmons]

Unbelievable work! Just amazing.

[phil744]

That looks beautiful :) :) :) How did you do the beveled edging??

Ahh! thats easy, an old tried and tested method i call "pinning"

Basically if you have a small milling machine like an X2 or even a decent bench/pillar drill clamp a piece of MDF to it, using a 1mm drill bit drill through the MDF then hammer a small tack into the hole carefully not to bend the tack, file off the head of the tack so you have a small pin protruding out of the MDF by approx 1mm

Like this..
http://i17.photobucket.com/albums/b52/madmini1/DSCF3623.jpg

You can use a standard 45 degree countersink bit, i have had a set of 4 flute endmills grounded down to a 45 degree chamfer and some rounded off to produce a radii from 0.5mm to 3mm, but a standard countersink works fine but you just need to run it at a higher speed, i know, just tried it.

Allign the countersink bit top dead centre to the pin in the MDF, adjust the mechanical stop or if using a bench drill adjust the work table up or down to gauge the size of chamfer you want, obviously the lower the countersink is to the MDF the bigger the chamfer, best try with a scrap piece first until you get it right (thats what I do)

And simply switch your machine of choice on, i find higher the speed the better the cut for acrylic, different materials require different speeds, for acrylic i set mine to 2500RPM.

Simply push the piece up against the pin, its hard to explain but you need to apply 50% pressure latrually for it to cut and 50% vertically to stop the piece from bouncing then move the piece in an opposite direction to the cutting face of the bit you are using (clockwise normally) not too fast and not too slow, if you go too fast you get big chunks being removed, too slow and you run the risk of overheating the job piece.

Like this *** PLEASE ALWAYS USE GOGGLES AND GLOVES, THIS PIC IS JUST TO SHOW YOU WHAT I MEAN****

http://i17.photobucket.com/albums/b52/madmini1/DSCF3624.jpg

It might look dodgy but it works, i have been doing this since school, you just have to practice.





Anyway, this is revision 2 once it was painted and screw holes countersunk, yet another piece that will make its first flight to the bin.:(

http://i17.photobucket.com/albums/b52/madmini1/DSCF3627.jpg

***note to self, tidy up in the morning, it looks like a 747 has actually crashed landed here, there are bits of Boeing everywhere!!***

Not bad for a days work, just noticed its just gone 3am here :(

http://i17.photobucket.com/albums/b52/madmini1/DSCF3628.jpg

[Lewis Simmons]

The colour on that fmc is perfect Phil. It's almost got a golden tint to it. Very nice.

[Matt Olieman]

Nice to have the know how and the right tools!!!! Thanks Phil, learned something new today :)

[Joe Cygan]

Phil,
Awesome,awesome,awesome!

[Padraig]

Hi Phil, just seen your thread here, Wow you have really fine tuned your skill. If you keep going at that rate, you`ll be able to form a business out of what you are doing, because from what I can see, your work is top notch! and theres lots of room for skilled, honest people like you in the Sim market.

Well done and great work!

[phil744]

Hi Phil, just seen your thread here, Wow you have really fine tuned your skill. If you keep going at that rate, you`ll be able to form a business out of what you are doing, because from what I can see, your work is top notch! and theres lots of room for skilled, honest people like you in the Sim market.

Well done and great work!

Your not the first person to say that and you will not be the last, right now i dont know, but i have to admit i do enjoy doing this sort of thing, every panel has its own set of unique challenges and as you have probably gathered im doing a few bits for people right now, im just glad i can help in some way, if i was to do this full time i would rather not offer complete sets for currently supported aircraft types, but rather build special "one offs" for people and help those with unsupported sims.

Anyway, more important things.. My Sim!! :p

Look first panel nearlly complete, well happy with it I am.
http://i17.photobucket.com/albums/b52/madmini1/DSCF3725.jpg

My plan is now to complete the cad work for all the aluminium backers, and basically get them laser cut by someone in one whole lot, you have probably noticed ive used another real panels backer to build my evac panel, however i am a real fan of the "tatty, worn, and used" effect, in my opinion it adds a whole lot of depth and realism to a panel. so i have decided to do this to my sim, i want to avoid the brand new look and rather the been in service for 10 year's look. This is going to sound mad but once i have all the backers done i will paint them in the yellow/green base coat then paint them brown, then im going to take the whole lot outside into the carpark and kick them around:o until they all look battered chipped and scratched, then toutch up using a brush if required!!!

Ok, for the past week i have stopped building because i have had some problems with the panels, it seems that i build one, its perfect, build another and its crap, so i did a small run of around 10 various pieces, ive changed the paint yet again, machine settings and now there all perfect again, let me introduce you to the revision 3 panels, ive even made the very first two pieces for the 767 aswell.
http://i17.photobucket.com/albums/b52/madmini1/DSCF3728.jpg

[ivar hestnes]

Very impressive. Looking good as all your pictures do:)

[Joe Cygan]

Keep up the awesome work Phil!

[Matt Olieman]

Phil, I just thought of something.... I've got a spare bedroom and a large garage with a sim.... I'll let move in the spare bedroom.... what do you say Phil, a deal??????? LOL

[phil744]

Phil, I just thought of something.... I've got a spare bedroom and a large garage with a sim.... I'll let move in the spare bedroom.... what do you say Phil, a deal??????? LOL

deal!:):):), can you fit a 76 and a 74 in your garage aswell?

[Matt Olieman]

I'll make room..... No problem LMAO :) :) :)

Oops.... maybe I should ask my wife first? :( LOL