727 Framework for Half-Shell

[Michael Carter]

I started again tonight after work. I'm still studying photos and making adjustments. It's very difficult to try to interpret some of these angles because each photo looks different from the next. Due to so many compound angles you never know if it's right untill it looks right from every angle you can find. There is also lens distortion from some photos and you never know what to trust and what to pass on.

Anyway, I adjusted the sidewall brace another 3.75" outboard along with the side window frame(s). I also studied some photos of the only actual interior piece I have to try and get the angle right for this before starting the aft end framework. This is about as close as I can get it with the photos I have.

Everything seems to line up. This thing is a lot bigger than I imagined. It's been a long time since I had a visit to a 727 cockpit.

I still have a bit of bracing and other support structure to cut and install. One piece at a time. It is amazing how much can be done with only one real piece for a frame of reference. This did make some decisions easier to make.

http://i63.photobucket.com/albums/h146/boeing722/cockpit7.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit8-1.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit9-1.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit010.jpg

[Tomlin]

Mike, why do I get the feeling that you have been telling a bit of a fib- You have plenty of room there for your sim! Of course, I realize that you may not be able to use ALL of that room, but you sure are making do with little space. The framing you're doing is adding so very much to your sim. I applaud your efforts and in time it's going to be awesome. Keep up the good work but dont beat yourself up if you get an agle off by 2 degrees there!

[Michael Carter]

Thanks Eric. No, I can't use all of this room as I wouldn't have much room to move around in. The chimney on the right is the big obsticle. Obviously I can't move it so I'm building around it. That's why there is no right side to my sim.

If I brought the whole thing out to clear the chimney and build the right side it would cut down on my room space considerably.

It's been a lot of fun taking it to the next level.

[Sunday]

Looks great! I know what you mean about bigger than imagined.

I built a protoytype out of 1x1's and was shocked when I saw how big it looked.

Keep up the good work.

[Michael Carter]

Thanks.

A little more work on the upper section today. That #5 window frame was a real bugger.

http://i63.photobucket.com/albums/h146/boeing722/cockpit012.jpg

And a shot of the installed trackball. I'm getting ready to try it out right now.

http://i63.photobucket.com/albums/h146/boeing722/TB1.jpg

[Michael Carter]

A couple more from working tonight:

http://i63.photobucket.com/albums/h146/boeing722/cocckpit014.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit013.jpg

I finally figured out how I'm going to build the interior since I can't find any.

After I get the proper supports in the correct spots for the O2 selector panel, mike selector panel, ash tray/cup holder, etc, I'm going to use hardware cloth (heavy screen) to shape the interior panels including the shallow depression for the steering tiller.

After it's shaped properly and I'm satisfied with it, I'm going to layer fibreglass cloth and resin over the hardware cloth.

I thought about chicken wire but it's too flimsy to support a shape and the fibreglass and resin, and the holes are too big.

Hope this works.

[Tomlin]

Mike,

Your hardware cloth idea is interesting. Please let us know how that works out as I had never considered that before. You've got my wheels spinning on other possible ways to skin this LJ shell than what we've been discussing.

[Michael Carter]

It's the only idea I could think of that was relatively cheap and easy to do.

Cutting that many compound angles and curves for the interior panels didn't sound too appealing. I suppose you could skin a whole shell with this method. It's light, and the hardware cloth is easy to work with and can be attached with staples. It's also stiff enough to support the fibreglass and resin.

[Michael Carter]

Started working on the sidewall today. This might not be quite as involved as I first thought. What angles there are, are not that severe and there aren't too many compound angles. The only curve seems to be the dish-shape for the steering tiller. I may use the fibreglass for this, or I may try and form a cone from sheet styrene. The edge of the O2 rack pretty well defines this shape and depth.

Although what is pictured is eight hours of work, it really wasn't too difficult. A lot of screws and Elmers Carpenters glue. Most of the time was spent fitting the individual parts together and studying photos.

The ash tray/cup holder doesn't go in that rack, it goes in the next rack to the left which I hope to build tomorrow.

I sat in it after I cleaned up the area. It's getting smaller with each days work. It is really starting to feel as though you are sitting in a real cockpit.

http://i63.photobucket.com/albums/h146/boeing722/cockpit02.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit03.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit04.jpg

[Joe Cygan]

Started working on the sidewall today. This might not be quite as involved as I first thought. What angles there are, are not that severe and there aren't too many compound angles. The only curve seems to be the dish-shape for the steering tiller. I may use the fibreglass for this, or I may try and form a cone from sheet styrene. The edge of the O2 rack pretty well defines this shape and depth.

Although what is pictured is eight hours of work, it really wasn't too difficult. A lot of screws and Elmers Carpenters glue. Most of the time was spent fitting the individual parts together and studying photos.

The ash tray/cup holder doesn't go in that rack, it goes in the next rack to the left which I hope to build tomorrow.

I sat in it after I cleaned up the area. It's getting smaller with each days work. It is really starting to feel as though you are sitting in a real cockpit.



Hey its great to see you working with wood after all the years of preaching about using real parts, great!

[Michael Carter]

Hey, when the real thing can't be found, we improvise, overcome, and adapt!

This interior is quite a bit different than a 737NG. No way I could use those interior panels...but I thought about it.

[ivar hestnes]

You are doing well Michael. Looking very good. Bet you have a good time with the woodworking and watching your half-shell slowly getting there:)

Looking forward to your next update.

:)

[Tomlin]

Yep, before you know it you will be posting up a new pic for your avatar showing it off!

[Michael Carter]

Thanks guys! I'm working on it right now.

I think I have enough sheet plastic to cover two or three interiors. Still doing the woodwork for now though.

I'll post another picture of todays work after while.

[Matt Olieman]

Look forward to see that Mike... I'm curious to see how it works for you. I still have a lot of interior work to do on my cockpit.

Matt O.

[Michael Carter]

Here's the latest after working today.

http://i63.photobucket.com/albums/h146/boeing722/cockpit06.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit07.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit05.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit09.jpg

[QF6228]

What a massive difference, Its really starting to take shape Mike, Nice work mate.

Damien

[Matt Olieman]

Nice work Mike :) :) :) Keep it up, .... obviously you are :)

Matt O.

[Michael Carter]

Thanks for the encouragement guys.

It's a good thing I restudied photos and my POH of the flight deck floor plan, I nearly made a huge mistake with the sidewall placement and angles.

There are two cubby holes aft of the ashtray/cupholder. The first is for mic and O2 mask connections and the second I think is just a utility hole for holding whatever will fit. It won't be much because it's pretty small. A template for the holes has been cut and is just standing there in position.

I also have that first support behind the cubby holes. The one I built at the wrong angle and discovered it while installing the side window frames. I'm afraid the first hole with the connections won't be deep enough with that 2x4 running behind it, but I think I can make it work. I need to get a couple of XLR panel mount jacks and contact Nick at APHS and see if he has a mask connector.

I don't want to remove it or cut the 2x4 as it is one of the primary supports of the whole shell.

[Michael Carter]

The side rack came today. I had to relieve about a 1/4" of the support to get it to fit and cut away some sort of mounting plate that was built in to the side of the rack.

As a bonus, I received 10 Dusz fasteners with the purchase. The module installed was only to ensure that I had the rack square in the hole. Being aluminum it's easy to distort the shape into a parallelogram which wouldn't be too good for mounting modules.

I bought a heat gun at the hardware store the other day. It works wonders on sheet styrene or ABS, Not sure what sort of plastic I'm working with since it was surplus. Probably ABS as it doesn't seem very brittle and bends easily.

I'm going to start covering in a day or two.

http://i63.photobucket.com/albums/h146/boeing722/siderack.jpg

[Michael Carter]

Thanks to Joe and photos of his 727 I was able to rebuild the vent panel to look a lot more correct than what I thought it looked like.

That is a 2.5" exhaust pipe coupler and formed sheet plastic as the covering for the cove above the pipe. The heat gun works great. Along with a lot of JB Weld for ataching the pipe to the wood, it was great as a gap filler with a bit of tape on the opposite side of the panel.

I still need to sand it down, fill it, prime it, and paint it.

The vent nozzle will be along from Aircraft Spruce in a couple of weeks.

Steinair AV125B:

http://i63.photobucket.com/albums/h146/boeing722/SteinairAV125B.jpg

Thanks Joe!!! Couldn't have done it without you.

http://i63.photobucket.com/albums/h146/boeing722/cockpit010-1.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit012-1.jpg

And the model for my work, Joe's 727:

http://i63.photobucket.com/albums/h146/boeing722/joescockpit09.jpg

[Michael Carter]

More work today.

Cut and fit plastic all day. I redid one section I wasn't happy with, and I'm still not to thrilled with the plastic up on the window sill. I may redo that as well.

Man, are my ankles and feet hurting right now.

http://i63.photobucket.com/albums/h146/boeing722/cockpit016.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit017.jpg

This section didn't turn out as planned because of the 2x4 support behind the wall of this utility section. I also inadvertanly glued the flat shelf to the supports and the supports to the sill plate so that wasn't going anywhere either.

I was going to cut another rack for the O2 and mic connections. Now I'll have to fake it. The second shelf is supposed to have some sort of a bin for storing something. I left it as a shelf since I have little room to set anything down in the sim.

http://i63.photobucket.com/albums/h146/boeing722/cockpit019.jpg

http://i63.photobucket.com/albums/h146/boeing722/cockpit020.jpg

[Tomlin]

Man that's really coming along. What's the name of that white material?

[Michael Carter]

It's ABS or styrene sheet plastic, .030". It's easy to work with and fairly strong if supported. Not quite sure which it is but I'm leaning towards ABS since it seems softer than styrene.

Not unlike what Boeing uses for their interior panels, but thinner.

I abandonded the fibreglass and epoxy resin idea because I don't have any ventilation down here. Too dangerous to do in the house.