Aerosim Solutions B737 simulator rebuild

[Aerosim Solutions]

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.






I'll post more pics as the build progresses,

Cheers Gwyn
www.aerosimsolutions.com.au

[makoy]

Looks great.
What material you use to pedals, gray plastic?

Marco

[Aerosim Solutions]

Looks great.
What material you use to pedals, gray plastic?

Marco

Hi Marco, that is 6mm PVC sheeting called "Trovidur" and the axle is 25mm round PVC bar drilled out to slide onto a 12.7mm (1/2") stainless steel axle. I use a lot of PVC as it is easy to machine and it becomes very easy to bend and form when heated with a hot air gun. This sheeting is the same material I make MIPs and consoles with.
Cheers, Gwyn

[jackpilot]

Great post. Please go on. 

[fsaviator]

Yes, please do go on!

My rudder attempt prior to deploying was a dismal failure.  I'll be looking to work at it again when I get back...  my footrests look great, as do yours, though!

Warren

[MLeavy737]

Looks like the real deal! I like it!


Mike Leavy

[Aerosim Solutions]

More assembly pics on the rudders, I made a tool to form the rudder hoops and it works great!






Cheers Gwyn

[Aerosim Solutions]

More pics...




I'll be starting the rudder mechanicals next, I've completed a simple design and just have to build it!

Cheers, Gwyn
www.aerosimsolutions.com.au

[ETomlin]

Gywn, You've got a really great solution going on here. Nice product in the making!

[fsaviator]

 

Couldn't find an emoticon for "drooling"

[jackpilot]

héhé

[XOrionFE]

Very cool Gwyn.   You are a remarkable engineer!

Scott

[fsaviator]

Jack, you never cease to amaze me.  Neither does Gwyn.

I've been contemplating moving to Australia when I retire as I like the way the Aussies apply common sense to problems in the world, without forgetting where they come from...  if I do, I'll have to move near Gwyn so I can learn from the master...  his CNC skills are pretty good.

[Maurice]

More assembly pics on the rudders, I made a tool to form the rudder hoops and it works great!



Cheers Gwyn

Absolutely brilliant!! Wish I had half your engineering skills.

Maurice

[NeoMorph]

Most tools look functional but that looks like it's part of a simulator in itself... very cool. Mind you, it looks like it could come from a Spanish Inquisition simulator heh.

Is it made out of plastic, wood or metal (the tool that is)... can't quite see. And is that "Gear" actually from a failed part of your cockpit that got re-purposed?

Oh and when you mentioned the Heat Gun and PVC it reminded me how easy it is to mould if you make a good base. We used to use Perspex sheeting to make custom PC cases. Those pedals though... they look really amazing.

[Aerosim Solutions]

Most tools look functional but that looks like it's part of a simulator in itself... very cool. Mind you, it looks like it could come from a Spanish Inquisition simulator heh.

Is it made out of plastic, wood or metal (the tool that is)... can't quite see. And is that "Gear" actually from a failed part of your cockpit that got re-purposed?

Oh and when you mentioned the Heat Gun and PVC it reminded me how easy it is to mould if you make a good base. We used to use Perspex sheeting to make custom PC cases. Those pedals though... they look really amazing.

Cheers guys, I really enjoy seeing my product development being appreciated. I have always had the idea of creating products to make it easier for other builders to create their sims and 'Aerosim Solutions' will stay focussed on making the "hard bits"!!!

Warren - Perth, Western Australia is the best city in the world but keep it to yourself ok, we don't want it getting too big! I would welcome any MC or CB member to visit "Aerosim" if they are coming to Perth!

NeoMorph - the tool is all PVC with a stainless jack screw and stainless alignment guides. The knurled wheel was a 10 minute cut on the CNC, I drew it in VCarvePro6. There is a clear acrylic washer between the form block and the knurled wheel to reduce friction, you can't see it in the picture. I really enjoy working with PVC as it is relatively cheap, easy to machine and can be formed into all sorts of shapes when heated. Stay tuned for my mechanical solution to the rudder project soon to unfold in this thread...

Cheers, Gwyn
ww.aerosimsolutions.com.au

[NeoMorph]

Ahh... I see how it works now... Very clever... Rough shape it and then put it on the tool and crank the gear to stretch it until it forms correctly. As the greatest amount of pressure is going to be on the bar supported by a metal tube the only time the PVC has pressure on it is when the toe brakes are used. My only worry would be those 3 supporting bits at the back of the pedal. Mind you I suppose you glued around the whole edge of the pedal which would support it and as the outer part isn't the bit that is hinged it doesn't matter so much.

I wonder if I can do something similar (but without a CNC machine it will mean it's Dremel time again). Luckily the ATR pedals have no cutouts... Can I borrow your tool idea Gwyn (only I'll have to stick with hardwood and steel for the support).

[Aerosim Solutions]

Hi all, more pics of this week's progress...







I just have a few more bits to make, another week probably then it's back to the customer's jobs...

Cheers Gwyn
www.aerosimsolutions.com.au

[Boeing Skunk Works]

Awesome design and engineering Gwyn.

Will you be offering separate components such as the pedal treads only?

[jackpilot]

Looking good
The arm seems relatively short...surface mount?
Nice and simple.
JP

[Hessel Oosten]

Gwyn,

See rather late this superb thread !
Thanks so much for sharing this knowledge with us !

Hessel

[Rob65]

Gwyn,

very nice. I love the tool you made to form the rudder hoops - this little helper stretches the hoops to the exact size needed - real clever!

I guess you are going to paint the pedals in their proper colors.
How do you make the paint 'stick' ? I know there are special plastic primers used for painting the plastic body parts for cars do these also work on PVC?

And what about wear?

-- Good morning, this is your flight instructor. Please take of your shoes and fasten your seatbelts 

Rob

[Aerosim Solutions]

Hi Guys, I did a lot more this weekend but no new pics yet.

Mike - It takes about 2 to 2.5 hours to make one pedal tread so I can't really see it being viable as a 'sole' product!!! (Is that a real joke there, hehe!) I would have to charge about $100 each and I don't think that would seem reasonable because the real thing would probably be cheaper. It's a shame really because I originally thought they would be a winner! I can now see the value in the Revolution rudders, they sure are good quality, I saw them in Ian Sisson's simulator. I enquired about buying pedals alone from Revolution but they will not sell them separately.

Jack - correct - surface mount. These will sit on the flat floor of my sim and the two sets will be linked via the bell cranks.

Rob - Painting PVC is quite easy once the PVC has been primed with the correct primer. I use a product called "Tangit". It removes the gloss and cleans the surface really well. I do this before gluing PVC also, I always use a good quality cyanoacrylate glue from Loctite. This stuff is awesome but very unforgiving if the parts aren't aligned correctly, it provides a serious instant weld. After priming a high gloss epoxy enamel will last years but I haven't decided wether to paint my pedals or not yet, I probably will!

I don't think I can produce these pedal sets competitively and in truth I don't like reproducing components that are made by other vendors, I'm just saving some bucks by making these pedals for my own sim. If this remains the case at the end of the product I will probably release all of my design drawings to the community, I'll make a DIY package with instructions and pics. The design is very simple and should be able to be copied I think.

Cheers, Gwyn

[XOrionFE]

I must say Gwyn,  they look awesome.   I myself took the easy way out and bought the real ones but I give you a lot of credit for designing and making your own.   Very nice.

Scott

[Aerosim Solutions]

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.

These are the parts that make up the brakes and rudder linkages

As always - KISS principle applied!

The brake plate has the gear teeth for the pot and the return spring, this plate is fixed to the pedal

The brake pots rotate 280 degrees so they should give smooth braking

The spring and link arm hangs down on the pedal coming backwards and the other gets stretched

This rose joint under the bell crank is for connecting to the second set of rudders

The lid opens for easy access

70 hours later....

Cheers Gwyn
www.aerosimsolutions.com.au