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5 Attachment(s)
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.
Attachment 4738
Attachment 4739
Attachment 4740
Attachment 4741
Attachment 4742
Looks the part hey? More soon on the rebuild and as always feel free to copy!
Cheers Gwyn
www.aerosimsolutions.com.au
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Re: Aerosim Solutions B737 simulator rebuild
Hey Gwyn,
Very, very nice idea for making the pedals. Wonderfull.
Regards, Wendy
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Re: Aerosim Solutions B737 simulator rebuild
Nice one, looking forward to seeing her revamped and in the flesh...
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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…. :shock:
Just curious - thanks for sharing and for sure this will be something to copy.;)
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Re: Aerosim Solutions B737 simulator rebuild
Quote:
Originally Posted by
Perik
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…. :shock:
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
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Re: Aerosim Solutions B737 simulator rebuild
Well, .. Congratulations on the Marriage :)
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Re: Aerosim Solutions B737 simulator rebuild
Wow... Love the footpedals!
Great job on those babies.
Polmer
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Re: Aerosim Solutions B737 simulator rebuild
Quote:
Originally Posted by
Westozy
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 ?
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Re: Aerosim Solutions B737 simulator rebuild
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Re: Aerosim Solutions B737 simulator rebuild
Thanks guys, here's some more pics of the rudders being built...
http://www.mycockpit.org/photopost/d...rming-tool.jpg
Tool for forming the rudder hoops
http://www.mycockpit.org/photopost/d...med-after-.jpg
A warmed up hoop is 'stretched' into shape
http://www.mycockpit.org/photopost/d...leted-hoop.jpg
A hoop ready for assembly
http://www.mycockpit.org/photopost/d...tted-to-ho.jpg
The hollow axle glued into place
http://www.mycockpit.org/photopost/d...ted-pedal-.jpg
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.
http://www.mycockpit.org/photopost/d...-completed.jpg
Four sets completed
http://www.mycockpit.org/photopost/d...th-footres.jpg
Four sets of pedals and footrests
I'll be starting the mechanical components of the rudders next!
Cheers Gwyn
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Re: Aerosim Solutions B737 simulator rebuild
Well Gwyn, I can see a new product for Aerosim :p Amazing work though, if only we were all that skilled :p
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Re: Aerosim Solutions B737 simulator rebuild
You're a bloody genious Gwyn, fantastically simple too.
Ken.
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Re: Aerosim Solutions B737 simulator rebuild
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Re: Aerosim Solutions B737 simulator rebuild
Hi guys, I've completed the rudder sets at last!
Well apart from a coat of paint but the mechanicals are done. The rudder pedals stay parallel as they travel over the arc and the return springs of good resistance and excellent self centering. The toe brakes have good travel with spring resistance and full analog braking capability via geared potentiometer drives. The centre box lid is hinged for easy access and it is held shut in the closed position with some small but powerful magnets. I'm really pleased with the outcome and I'm looking forward to installing them in the sim once the new floor has been fitted.
http://www.mycockpit.org/photopost/d...dder_parts.jpg
These are the parts that make up the brakes and rudder linkages
http://www.mycockpit.org/photopost/d..._mechanism.jpg
As always - KISS principle applied!
http://www.mycockpit.org/photopost/d..._mechanism.jpg
The brake plate has the gear teeth for the pot and the return spring, this plate is fixed to the pedal
http://www.mycockpit.org/photopost/d...entiometer.jpg
The brake pots rotate 280 degrees so they should give smooth braking
http://www.mycockpit.org/photopost/d...ng_springs.jpg
The spring and link arm hangs down on the pedal coming backwards and the other gets stretched
http://www.mycockpit.org/photopost/d...Hinged_lid.jpg
The lid opens for easy access
http://www.mycockpit.org/photopost/d...joint_link.jpg
This rose joint under the bell crank is for connecting to the second set of rudders
http://www.mycockpit.org/photopost/d...s_finished.jpg
70 hours later....
Cheers Gwyn
www.aerosimsolutions.com.au
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Re: Aerosim Solutions B737 simulator rebuild
Once again, bloody amazing Gwyn. Simplicity is so beautiful and I love the easy access lid too, always thinking about maintenance hey :)
Cheers,
Ken.
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Re: Aerosim Solutions B737 simulator rebuild
bloody amazing Mr Gwyn, what more can i say. Nice 1. !!!!
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Re: Aerosim Solutions B737 simulator rebuild
Wow, I feel like an absolute noob when I see your work!
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Re: Aerosim Solutions B737 simulator rebuild
Quote:
Originally Posted by
capetonian
Wow, I feel like an absolute noob when I see your work!
don't we all :o
one of the most talented chaps i've seen with his hands is our Gwyn.
well done matey :o
rgds
ian
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Re: Aerosim Solutions B737 simulator rebuild
amazing work! thanks for sharing!
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Re: Aerosim Solutions B737 simulator rebuild
Congratiolations Gwyn, thats is a very well made rudder. To make such complicated mechanical structure in one time, I think you designed it with someting like SolidWorks (or another 3D CAD program). If thats the case would you share the file with us?
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Re: Aerosim Solutions B737 simulator rebuild
Absolutely stunning. BTW, curious about the measurements.
JWS
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Re: Aerosim Solutions B737 simulator rebuild
As Always!!!!! AMAZING WORK Gwyn... WOW!!!!!!
Matt Olieman
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Re: Aerosim Solutions B737 simulator rebuild
Hi guys and cheers for all the positive comments, always a buzz!
I really enjoyed designing and building these rudders, I did it in VCarvePro6 btw. I think the time it took to build them makes them unviable as a product, they would need to be priced at around AUD$1500 per set and Revolution already produce a similar set around this price. I am planning to develop the pedal plates as a seperate product, I have already had a few enquiries on these already. I'm thinking of releasing my plans and VCarve files with a tutorial if I ever get time to make one!!!
The rudder sets are sized to suit my own simulator frame, they are 450mm wide, 370mm high from floor to top of pedal and 490mm deep from the base plate to the back of the bell crank. They work extremely well and I hope to fit them to the frame this weekend, more pics soon if that happens.
Cheers Gwyn
www.aerosimsolutions.com.au
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Re: Aerosim Solutions B737 simulator rebuild
Hi all, see a video of my pedal sets here...
http://www.youtube.com/watch?v=zqlS10I6tZc
Hope you like it!!
Cheers, Gwyn
www.aerosimsolutions.com.au
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Re: Aerosim Solutions B737 simulator rebuild
Awesome end result Gwyn. If someone took upon themselves to mass produce your design they'd sell like hot cakes!
Cheers and thanks for sharing this,
Ken.
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Re: Aerosim Solutions B737 simulator rebuild
VERY NICE!!!!! Can't wait to take them for a spin!
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Re: Aerosim Solutions B737 simulator rebuild
Gwyn, you have to make plans and a tutorial, this is just way to cool. I have have one pedal off a 757, but have wanted to use it to make a set. Please make the plans and a tutorial.
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Re: Aerosim Solutions B737 simulator rebuild
Quote:
Originally Posted by
jsfboat
Gwyn, you have to make plans and a tutorial, this is just way to cool. I have have one pedal off a 757, but have wanted to use it to make a set. Please make the plans and a tutorial.
Making plans and a tutorial is a huge task in itself, but as I have no plans to mass produce the rudder sets as a complete plug n play unit, I will make plans to share with the community when I find some time to do it! I do offer the pedals themselves as a stand alone product, they will be on my website soon.
Cheers Gwyn
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Re: Aerosim Solutions B737 simulator rebuild
Hi all,
I have progressed a little more on the MIP this week which included a trip to Bunbury to fly Darryl's amazing Spitfire and deliver his latest part, cheers Darryl!
I removed the monitors from there casings and attached them to the back of my MIP with clamps made from PVC. The two outer monitors are 19" ACER X193HQ models and the centre monitor is a regular 17" LCD turned on it's side. The SimAvionics software allows gauge rotation and this monitor will display the EICAS, 3 standbys and the flaps gauge, I'm not sure if the yaw damper is modelled. Installing this monitor means there is no room for the autobrake switch to be fitted into it's own panel so I have mounted it off to the side and it will be driven by a trace wire cable - more on this later when I fit the cable.
http://www.mycockpit.org/photopost/d...737-MIP-01.jpg
http://www.mycockpit.org/photopost/d...737-MIP-02.jpg
http://www.mycockpit.org/photopost/d...737-MIP-03.jpg
http://www.mycockpit.org/photopost/d...737-MIP-04.jpg
http://www.mycockpit.org/photopost/d...737-MIP-05.jpg
More soon,
Gwyn
Aerosim Solutions
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Re: Aerosim Solutions B737 simulator rebuild
Gwyn,
Can I ask what material the front panel is made from and what is its thickness.
Thanks.
shim
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Re: Aerosim Solutions B737 simulator rebuild
Quote:
Originally Posted by
be3978
Gwyn,
Can I ask what material the front panel is made from and what is its thickness.
Thanks.
shim
Hi Shim,
The panel is cut from 6mm Trovidur PVC, it will be primed and painted in epoxy enamel before mounting.
Cheers Gwyn
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4 Attachment(s)
Re: Aerosim Solutions B737 simulator rebuild
Hi all,
At last I have cleared the backlog of orders and made another start on the Aerosim Solutions B737 simulator! I have just sold my old throttle and overhead so I thought I would start by making a new TQ. Here are the first pictures of TQ handle bodies, the backing plates that the lever handles attach to will be made from 3mm aluminium plate.
I'm not really planning to release a B737 TQ as a product as there are already so many available elswhere but I am thinking about releasing my VCarvePro CNC files at the end of this build when the set is completed for other CNC users. Stay tuned for more progress on the TQ build as it happens!!!
Attachment 6045
Attachment 6046
Attachment 6047
Attachment 6048
Cheers Gwyn
Aerosim Solutions
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Re: Aerosim Solutions B737 simulator rebuild
Quote:
Originally Posted by
be3978
Gwyn,
Can I ask what material the front panel is made from and what is its thickness.
Thanks.
shim
Hi Shim,
I used 6mm Trovidur PVC sheeting for the MIP, it is great stuff to work with and quite strong!
Cheers GP
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Re: Aerosim Solutions B737 simulator rebuild
Like that idea of vcarve files nice !! keep us posted Gwyn
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3 Attachment(s)
Re: Aerosim Solutions B737 simulator rebuild
Hi all,
More progress this week with the lever handles completed, I'll start design work on the housing next. I will be making molds for producing the engraved throttle knobs shortly!
Attachment 6090
Attachment 6091
Attachment 6092
Cheers Gwyn
Aerosim Solutions
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Re: Aerosim Solutions B737 simulator rebuild
Hi Gwyn,
As I understand, there will be no physical limitation to pulling reversers while the throttle levers are not in idle, right? That's how I see it in the lever mechanisms at least...
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Re: Aerosim Solutions B737 simulator rebuild
Quote:
Originally Posted by
Efe Cem Elci
Hi Gwyn,
As I understand, there will be no physical limitation to pulling reversers while the throttle levers are not in idle, right? That's how I see it in the lever mechanisms at least...
Hi Efe,
Absolutely correct, a real TQ will not allow reverse to be activated unless the levers are in idle. I decided that a physical interlock is not neccessary for my own simulator as FS won't allow reverse higher than idle anyway and it would mean a lot of additional work. Whilst it would be great to have 100% accuracy in operation of all the components I make, I try not to lose sight that I am building parts for hobby simulators. When I make components for my own simulator I am also focussed on the fact that I might be developing a new product for Aerosim Solutions. Keeping cost and complexity to a minimum is high priority for me, (the KISS principle!) I will probably not release a B737 TQ as there are already so many available out there and the new FDS Jetmax unit looks such a winner, that would be my choice if I couldn't make one myself! I might however offer to sell components such as thrust levers, handles, TQ knobs, lightplates etc. I really like designing "make it easier" parts for the community and the variety of custom orders keeps it interesting. The "closed for trading" message on my website has only slowed business slightly and orders keep on coming despite the message! I will re open mid year bigger and better, hopefully with a switch to fulltime production!
Cheers Gwyn
Aerosim Solutions
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5 Attachment(s)
Re: Aerosim Solutions B737 simulator rebuild
Hi all,
I made some good progress on the Boeing this week after catching up on customer orders. I made a full scale drawing of the side elevation of my sim frame in VCarvePro6.5 which made it a lot simpler to design the shape of the MIP stand. I still had to cut out the pieces by hand as the parts are too big for my CNC machine, I really need a bigger machine! I built the CDU bay/Mip stand out of 12mm PVC and 10mm white acrylic sheeting which made it a little on the heavy side but it sure is strong, the mip is around 18kg with the monitors fitted. The beautiful FDS Promax CDUs look fantastic in there, I will have to remove the Dzus fasteners and fit normal screws later and this will allow them to sit another 6mm lower in the apertures. The display monitor between the CDUs is a 10 1/2" touch screen I picked up on Ebay for $150, it was a little too long but this has turned into a fortunate positive, the monitor controls are just visible. When I make the TQ stand I will make a little access cover for the monitor buttons. If you look closely at the MIP you will see the three monitor controller card mounted in the lower part of the square bezels, this will make monitor adjustments a lot easier. I have made the hinged strips but haven't fitted them yet. The auto throttle motors have arrived so the TQ will be the next item on the 'to do' list!
Attachment 6526
Attachment 6527
Attachment 6528
Attachment 6529
Attachment 6530
Cheers Gwyn
Aerosim Solutions
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Re: Aerosim Solutions B737 simulator rebuild
Gwyn,
you never cease to amaze me... It looks fantastic. I'm also building my new MIP right now and I thought it looked great but now:-(
I'm building out of sheet steel though. Fes' up, Gwyn, you have a PVC fairy down under, don't you? You must get great prices on PVC.
Seriously though, looks good. My CNC is down right now as I blew it up trying to wire in some proximity limit switches but I just got my new board and hope to be up and running soon.
Cheers!
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3 Attachment(s)
Re: Aerosim Solutions B737 simulator rebuild
Cheers Warren, PVC fairy LOL! I do like working with PVC, it makes it easy to produce accurate parts with a good finish. The only downside is the weight because of it's density. My rudder sets are about 9kg and quite expensive to post.
Here is the result of the first 10 hours on the trim wheels, again fabricated from PVC!
Attachment 6565
Attachment 6566
Attachment 6567
Cheers Gwyn
Aerosim Solutions