Dual flight control build

[Shawn]

I have started work on a set of dual controls. The plan is toe brake pedals and centre stick.

I'm still trying to work out what I forgot before committing to welding the pedals.

8653

Working on the centre stick assembly, I just bought a cheap DIY powder coating system and so far I couldn't be happier with the results.


http://img593.imageshack.us/img593/9205/vff7.jpg


You will just have to imagine the axle running between these parts.


http://img208.imageshack.us/img208/1903/jzje.jpg


http://img199.imageshack.us/img199/8765/la4x.jpg


Shawn

[Avro748]

Very nice! I wish I had more time to work on my build, I'm getting tired of making so many mouse clicks.

[Shawn]

Made a few changes to the gimbal assembly. I think this is going to be way over engineered :D

8654

Shawn

[Shawn]

Some more progress...


http://img541.imageshack.us/img541/5558/ki0f.jpg


http://img31.imageshack.us/img31/2007/r6vg.jpg


Shawn

[Shawn]

I decided on a stick design, for now....

8655

8657

Shawn

[Shawn]

Done for today but made some good progress :D


http://img401.imageshack.us/img401/8863/a2uw.jpg


http://img545.imageshack.us/img545/7720/1ao8.jpg


The controls are about 4" to wide but I won't trim the bars down till I'm sure exactly how wide I want them. I was going to make them the 25.250" to match the Jetranger but a bit more elbow room might be nice.


Shawn

[Shawn]

I plan to fly fixed wing from the left seat and helicopters from the right. Because I'm using simple grips I wanted to come up with a way to add some additional switches to the FW side. Things like electric trim, flaps etc. This is what I came up with this morning. Its adjustable forward and backward to allow for different hand sizes/preference.




http://img845.imageshack.us/img845/6214/pjdy.jpg


http://img401.imageshack.us/img401/4975/1gim.jpg


I haven't decided yet if it looks goofy or not yet, it is comfortable to use though.


Shawn

[Avro748]

Looks great! Subscribed!

[Shawn]

Thanks Avro

8664

Shawn

[Shawn]

Got the counterbalance built and it seems to balance where I want it. Have to build the brackets for the hydraulic dampers and bring the controls closer together by 4".


http://youtu.be/BA0zp1mVD9E

Shawn

[Shawn]

I got the roll damper installed today, hopefully I will have time to do the pitch tomorrow.


http://imagizer.imageshack.us/v2/1024x768q90/802/zt54.jpg


http://imagizer.imageshack.us/v2/1024x768q90/69/9akl.jpg


Shawn

[Shawn]

Managed to get a bunch of fiddle bits finished today and cut the plate I'll use for the rear support. Quality control is taking a hard look at things in this photo, I'll be sure to have issues I need to fix...

8681

[Shawn]

So last night I noticed that during rapid roll movements the spherical rod end were moving on the bolt I used to hold them. There was .050 difference in the bolt diameter and the hole in the rod end. Tightening them helped a bit but wasn't the solution. I went to town to look for some cheap ball joints with a stud but all the cheap ones had the same runout. So I decided to give something a try and it worked like a charm. I turned down a steel rod to .080 oversized and pressed it into the hole of the rod end. The force of the pin expanded the steel ball insert to a snug fit with the brass sleeve, no measurable slack. Only took me three tries :D .010 oversized bent the pin before I could force it in and .050 was a nice fit but didn't effect the total runout. Saved me a few buck and was a good exercise in turning to a precise diameter.


http://img706.imageshack.us/img706/6877/dlj2.jpg


Shawn

[50fighterfan]

Love the counter-balance idea! When I saw it, a little light bulb when on over my head and I said, "Ah ha!" I happen to have an old el-cheapo telescope that I bought at a yard sale years ago which has a similar, if somewhat less refined, counter balance!

Thanx!

[Shawn]

My pleasure Fighterfan, not sure where I first saw the idea but like you it made a light go on. :D

[Shawn]

Started work on the panels for my generic simpit.

9177

9178

[Shawn]

This was something I saw (probably on this site?) and kept in the back of my mind for later. It's a fake fuse panel that will give me access to a few key strokes I normally use in the cockpit but aren't exactly aircraft related. The fuse holders are modified to fit a small push button switch.

http://i.imgur.com/lAHBjcvl.jpg
Shawn

[geneb]

That's clever. :) g.

[Shawn]

Thanks Geneb, not my idea but I do thank whomever had the idea and posted it previous to me. ;)

I did do a bit more work on the controls today, the main axle will be connected to this linear slide via springs, the slide will be attached to a linear actuator giving me a basic electric trim. Once again not my idea but I liked it when I saw something similar on a dual yoke setup.

9188

Shawn

[Shawn]

Autopilot panel prior to paint and engraving.

http://s28.postimg.org/6h7h92j2l/image.jpg

[Shawn]

http://s8.postimg.org/ij4q7zt7p/image.jpg

[Per Alm]

Cool! Great stuff!!!

[Shawn]

Three position flap lever

94169417

Shawn

[Shawn]

More re work done on the pedals for the fixed wing side.

9509

[Shawn]

http://s18.postimg.org/s62vtrh2x/image.jpg

[Shawn]

I started on the first of many gauge bezels for the multiple panels I plan to build for the generic sim. I was having issues cutting circles with my cnc mill but I seem to have sorted that out by increasing how far ahead mach3 reads the g-code. The outer section of the bezel was cut from PVC board while the inner black section is a section of PVC pipe that i cut to length and then put a deep fillet on the inside. I was hoping the fillet would increase the viewing angle of the gauges, it's much better than the previous gauge bezels I have made with no fillet. This first set of bezels will be for a 4 engine, engine panel. I also plan a twin engine turboprop, piston and Jetranger panel. The Jetranger panel will be a bit of a stretch as the engine gauges will be displayed on a centre monitor with pilot and copilot gauges on monitors on either side.


http://s27.postimg.org/6uzrrb0zz/image.jpg (http://postimg.org/image/6uzrrb0zz/)


http://s27.postimg.org/uxglm6hn3/image.jpg (http://postimg.org/image/uxglm6hn3/)


http://s27.postimg.org/62x3s3wsv/image.jpg (http://postimg.org/image/62x3s3wsv/)

[Shawn]

Just a couple WIP pics of the annunciator panel.

973797389739

[Shawn]

Initially I was going to use Hall effect sensors because there easy to setup and don't require additional gearing but have decided to cut my own gears and make things harder than they need to be :D

[Shawn]

I'd be interested in seeing the final setup with HE sensor and the magnet Rhys.

Cheers
Shawn

[Shawn]

Got a few more panels built.

http://s15.postimg.org/fvgv5qo7f/image.jpg (http://postimage.org/)


http://s15.postimg.org/bxtlgc1e3/image.jpg (http://postimage.org/)

[Geremy Britton]

Once again, very nice, I like your work, please keep us updated with photos.
Best Regards

[Shawn]

Thanks Geremy, coming from you that compliment is of the highest order. Progress is slow but I'll be sure to add photos as I get parts done. I'm working on a plan for the seats right now so hoping to be welding by the weekend : )

[Shawn]

I have started work on the instruments that I won't be able to display on a LCD monitor. I have had Mike's book on building simulated aircraft instruments for years and finally feel like I might be able to actually build one. First of will be a simple flap gauge and hopefully a whiskey compass. This rendering is just a test to get a bit more familiar with Fusion 360.

http://s12.postimg.org/thyy3czlp/bezel2.png (http://postimage.org/)


Shawn

[Shawn]

Lots of time to sit and think about things but not much actual building time. I'm having a go at designing a rotary damper to try and get a better hydraulic feeling from my DIY controls. I have changed the design a fair bit since taking these renders but the overall idea is the same. If they work I'll post the results.

http://s21.postimg.org/cstskuxh3/Rotary_Dampner_5.png
http://s21.postimg.org/yqq9enchj/Rotary_Dampner_4.png

[Fan of Flying]

Very nice Shawn.

Mitch

[Shawn]

Thanks Mitch, I'll be surprised if it ever gets built but I'm having a great time designing parts with Fusion 360. Far sight better than what I used to use for aircraft in Fs9.

Shawn