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737 Throttle Conversion OC + ProSim

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sobsidian:
[UPDATE 7/22/2014 -- Added SIOC Script]

Hey Everyone,

I have converted a real 737 TQ and motorized it along with interfacing it for OpenCockpits DC Motor Plus card, and ProSim. I can attach the SIOC script later once I remember to grab it next time on the sim.

In the meantime, I'll leave you with some videos and more or less a bill of materials on what I used to convert it. I'll also be creating a detailed blog post about some of the thought process and "brick walls' along the way.

I'll be getting a bunch of photos in the coming weeks also once I finalize everything as to provide some references for anyone else going down this road.

Lastly...huge Thanks to FredK! I stole most of his ideas and saved me a lot of time.

Bill Of Materials:
Various:
1 - Opencockpits DC Motor Plus Card
2 - String Pots (PA-LX-10)  You'll need to call Unimeasure directly to place the order
2 Slip clutches (S98CA6MMOC320838 from SDP-SI.com) A7Z32MPB008MP 8mm Bore, Pillow-Mounted with PTFE
2 6mm to 8mm Couplers (connects the motors to the slip clutch) DumpsterCNC.com  // Coupler Size "A" // SAC1: Side 1: 6mm bore, Side 2: 8mm bore
2 Pillow Blocks (connects free end of slip clutch to base)
1 Car door actuator for parking brake & probably a switch (this may work for someone, but I was not happy with this approach, in the process of changing it using magnetic latches...check back for updates)
1- Steel cable for pulleys - http://www.amazon.com/gp/product/B003YDLX3I/ref=oh_details_o09_s03_i09?ie=UTF8&psc=1
1 - Steel cable cramps - http://www.amazon.com/gp/product/B0038YY25Y/ref=oh_details_o09_s03_i04?ie=UTF8&psc=1
1 Servo for Speed Brake, Hitec HS-815BB (could not use DC motor card with this, had to use standalone Opencockpit servo card)
1- HS-322HD Servo for trim guage
1 - GHM-12 Gear Head Motor 12VDC 30:1 253rpm -- Lynxmotion.com
2 - Alps RSAON1119A02 10K ohm thin B taper (linear) (for Flaps and Spoiler position)
1 - Sprocket for trim motor. Martin Roller Chain Sprocket, Bored-to-Size, Type B Hub, Single Strand, 35 Chain Size, 0.375" Pitch, 11 Teeth, 0.5" Bore Dia., 1.502" OD, 1.0625" Hub Dia., 0.168" Width -- http://www.amazon.com/gp/product/B0045JJVRU/ref=oh_details_o04_s00_i01?ie=UTF8&psc=1

From Grainger online:
1 - Item no: 2W092 #35 chain roller (from trim wheels)
1 - Item no: 2W092 #35 master chain link

Hardware Store:
Stainless Steel plates from local hardware store to build brackets and braces
various nuts, bolts, metal and wood screws

ServoCity List:
2 -  634184 8mm shafts for sprocket & clutch mount (connected from 6 to 8mm coupler to clutch. 3 inch is too big, buy a few 1-2 inch versions)
3 -  MM-250 precision motor mounts (2  for throttle, 1 for trim wheel)
2 - (634182) (17.04.03) 5/16 inch x2 inch Precision Shaft (this shaft connects the sprocket/clutch portion to the pillow block)
2 - 98847A005 4-40x12 inch Stainless Steel Threaded Rod (may want 2 additional incase you cut one inncorrectly)
10 -  (10756) (09.04.02) 4-40 Linkage
6 - (C250) .250 inch  Metal Chain (12 inch) and 1 connecting link (to link attach throttle cable to sprockets)
1 - (CHB475) .250 inch Chain Breaker to get chain length precise
1 - (545576) (06.12.03) 6mm Bore Set Screw Hub (0.770 inch) (attached to trim wheel motor, and then attached to hub sprocket below)
2 - PG12-200P 15rpm precision gear motor
2 - RHS-250-24 24 teeth #25 plastic sprocket gear (had to drill holes in them to attach to the clutch plate)

sourcingmap.com: (for parking brake magetic catch. Have not figured out which one to use yet, but ordered all 3)
a14010700ux0238         DC 12V 5mm 560g 1.2lb Push Pull Intermittent Electromagnet Solenoid      1
a13122300ux0016         DC12V 0.2A 2.4W Open Frame Push Pull Solenoid Electromagnet 0mm 500g 6mm 30g      1
a13121700ux0045         12V 7.5W Pull Type Open Frame Holding Force Solenoid Electromagnet


Lastly, here are the videos

This first video is pre-fab and walks through the basics of how the throttle operates.
http://youtu.be/a5m1Nvz_pMQ Small | Large

This video is after I've gotten about 90% of the conversion done.
http://youtu.be/fcwC_Qei7rs Small | Large

Cheers!
- Shawn

Aerosim Solutions:
Nice work, thanks for sharing! Gwyn

quid246:
Nice work!

Karl737:
Great work!

FredK:
Great documentary!

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