Follow along as I convert a customers real 737 throttle quadrant for use in his flight simulator. It will be fully motorized and offer the durability of REAL internal Boeing parts and select aftermarket parts to make it fully compatible with FSX.
1st stage is disassembly and cleaning, see pics below. I many more if someone needs to see them for reference.
Rob
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Below is picture of the Clutch set-up and chain drive gear. This will allow movement of the handle with the motor engaged as well as the correct amount of force needed to move the lever as in the real plane.
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Rob. This is insane. I love it. Please post as much of the progress as you can. I cant wait to watch this progress.
Thanks a bundle.
Trev
After you remove the electrical components, wouldn't it be possible to just hot tank and steam clean one of these so disassembly wasn't required?
Quote from: Boeing Skunk Works on September 21, 2011, 04:37:23 AM
After you remove the electrical components, wouldn't it be possible to just hot tank and steam clean one of these so disassembly wasn't required?
Yes, you could do it that way as well but when you disassemble it this way it allows more room to mock up the set-up and install certain components. It actually isn't that hard to take apart once you have done one. Quite enjoyable if I must say. :)
Rob
Looking at that second picture and how gross it is inside has put me off flying in real life. Don't they ever clean the things after the leave the factory? I know the strip the engines down but if the TQ has a problem then it doesn't matter what state the engines are in.
I'm not a coward but looking at that TQ just gives me the shivers. ???
My first real sim was a real 737 shell, no don't clean in most areas in the cockpit. Lol! In fact it is a modern wonder/slash miracle how these millions of parts from rivets to resistors even fly. A mere 1/8" of aluminium seperates you from comfort and death! Wow! - stared at that cockpit daily for a few years in pure amazement at the engineering.
Actually it explains why real certified plane parts are so expensive. The are expensive because they are made to stand a beating for many years to come. When you realise the age of some of these planes it is a wonder they are flying anyway. Lets face it, the engineers must have done a wonderful job to keep them airworthy for so long.
All hail the engineers! :D
I have motors on the way for the lever's. More pics soon.
Hi Rob,
Your polyclutch.jpg is not loading for some reason. Can you check?
Thanks a lot,
Denis
Below are some pictures of the trim wheel motor installed and the Park Brake release actuator installed.
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Good work Rob...
Keep the pics coming..
Jack
Here are the Lever drive motors with the Polyclutch installed and #25 chain drive gear installed.
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Here is a picture of the Park Brake Lever now attached to solenoid that snaps the park brake off when you tap the toe brakes.
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Here is the Spoiler lever side of TQ painted and Park brake Lamp cover installed.
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Below you will see the Spoiler Light plate cleaned, touched up and installed. I have reassembled the Inner workings of the TQ in preparation for installation of drive cables and motors.
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Looks great, Rob! Amazing work!
Here are 2 pictures of before and after on the flaps lever cover and touched up light plate which was in bad shape. I also had to fill in the hole left by the removal of the stab trim lamp.
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Here is picture of the trim motor and chain drive installed. Works great! #35 roller chain and 10t drive gear.
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Rob,
What hardware/software setup will you be using to drive the TQ motors? I ask because I am at bit of a road block and since you are also using DC motors, just wondering how you're going to do it.
Thanks,
Matt
P.S.- Brilliant pictures, quite amazing to see
The progress is unbelievable. 2 weeks ago it was just a dirty box and look at it now!
Looks great Rob
Mine is next! ;)
Scott
Thanks Rob for your progress pictures and information provided!
Great Job, very useful information. More pictures for motorized mechanism!
Thanks a lot,
Denis
Quote from: matta757 on October 02, 2011, 05:28:27 PM
Rob,
What hardware/software setup will you be using to drive the TQ motors? I ask because I am at bit of a road block and since you are also using DC motors, just wondering how you're going to do it.
Thanks,
Matt
P.S.- Brilliant pictures, quite amazing to see
Matt,
This project will be using a custom designed Interface from Smart Sim Tech that will handle all in/outs and motor drivers all in one usb card! Talk to Tyler if you would like more info.
Rob
Quote from: 727737Nut on October 02, 2011, 04:13:57 PM
Here is picture of the trim motor and chain drive installed. Works great! #35 roller chain and 10t drive gear.
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What an excellent job !
does that chain fit the original Trim chain wheels of the throttle ?
I'm currently having my real TQ motorized and cant find a fitting chain (and chain wheel for the motor end) here in holland.
Stef
Quote from: dnoize on October 04, 2011, 10:54:13 AM
Quote from: 727737Nut on October 02, 2011, 04:13:57 PM
Here is picture of the trim motor and chain drive installed. Works great! #35 roller chain and 10t drive gear.
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What an excellent job !
does that chain fit the original Trim chain wheels of the throttle ?
I'm currently having my real TQ motorized and cant find a fitting chain (and chain wheel for the motor end) here in holland.
Stef
Stef,
Yes, that is correct. It uses the original chain sprocket which is #35 chain here in the USA. The motor sprocket can be from 10t to 15t depending on RPM of motor being used. I used a small gearhead motor due to space but a larger remote mounted motor could be used also.
Rob
Got the lever drive motors installed today. Waiting on the string -pots and custom pulley bracket to arrive.
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Rob,
nice work, where did you get the clutches ? I'm looking for them a long time.
Uwe
Quote from: ekznamu on October 04, 2011, 09:56:55 PM
Rob,
nice work, where did you get the clutches ? I'm looking for them a long time.
Uwe
Ployclutch.com then use the link to find a dealer nearest to you. Also there are a few mail order places that have them but they were actually higher priced.
Rob
Not to hijack Rob's post Check my new post on Polyclutch.
Jack
Thank you both, an excellent source for that stuff.
It's not easy to appreciate the force needed to transmit the power.
Rob, what kind of clutch did you use for the lever driver motors ?
Would be SAS20 a good choice ?
Thanks
Uwe
Hello,
I used the SAO20-8mm I think it is important to have the adjustable one to compensate for different variables in the installation. The SAS20 would probably work but again it depends on how your lever system is built.
Rob
Quote from: 727737Nut on October 04, 2011, 11:55:46 AMStef,
Yes, that is correct. It uses the original chain sprocket which is #35 chain here in the USA. The motor sprocket can be from 10t to 15t depending on RPM of motor being used. I used a small gearhead motor due to space but a larger remote mounted motor could be used also.
Rob
Thanks a million !!
Time to source a # 35 chain in the US then !
Thanks again
Stef
Just a quick update, had to order new motors as the ones i had did not work good enough for my standards. I did get the rest of the light plates cleaned and tested and completed the painting. Motors should arrive tomorrow so more progress soon.
Rob
Thanks for the update Rob! Can't wait for more pictures! 8)
Well I finally got the new motors installed for the throttle levers. Turned out really good with the chain to cable hardware I used. With 5vdc applied to motors, the levers move nice and smooth!!
Next up is the string pot install and then the spoiler lever drive and trim indicator drive. The 3rd pic is of the trim indicators and upper side panels. Compare to original pic above in 1st post. Just a slight improvement. :)
Rob
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Outstanding work, Rob! :o 8)
Bloody unreal Rob!
Where the f--k did you get the trim indicators panels?
I have one nice one and one crappy one on my -300 TQ
Nat
Thanks guys! Nat, those are far from perfect. ;) I just touch of the edges and clean them really well.
I got the String pot's installed on the levers. Working on Flaps now. Post more pic's later today.
Rob
Hey Rob,
Your doing a fantastic job. I'm really looking forward to seeing the finished product and up and running. You will post a video of it when it's finished ?
OK, Got the string pot's installed. As usual, they were easy to install and work flawlessly! :) The flaps pot turned out really nice. I may redo my own now. lol As always, I have more pics if anyone needs them for reference. The cable I use is 1/16" 7x7 wire rope. I install a lead ball (aka sinker) around cable and drive/wedge into original location on lever wheels. Then route cables around pullys to the motor/clutches. Simple and tough.
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Here a couple of pics of the TQ reassembled. I think it looks pretty good compared to the original photo of the TQ when i got it. Hope Nick is pleased. Lots of man hours getting it to this stage. I have a few touch-ups to do and finish wiring and spoiler servo install. Getting closer now. :)
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I just wanted to add that although it looks like new, that is exactly what I didn't want. In person it looks like a used but in good shape, 737 throttle. I don't want a so new it looks like a toy thing. lol It maintains it's personality that way. Just like in a real plane where things are touched up by hand if at all.
Rob
Rob,
Your work is absolutely incredible! Cant wait to get mine over to you!
Scott
Either way Rob, your work on that TQ is great. As I said before I can't wait to see it in action working like the real thing. Totally profesional job. Fair play !
Rob, I can't say enough to praise, and it's only looking at the pictures now! :rock: :rock: :rock:
I bet when I get it it will look even better. Exquisite work!
Thanks a million,
Nick
This is looking so fantastic :)
Couldn't believe the dirt in there in the very beginning!
Hi,
Your job looks fantastic!!! I'm going thru the same process, and I'm just stuck on how to remove the trim wheels. Can you post some pics / tips?
Also, I'm located in Switzerland, and I find difficult to find required mecanical pieces (motors, chain sprockets...) Would you have some pointers on where did you buy them? Maybe I can order online. I saw another colleague here on the forum from NL, maybe we could even order a batch of pieces and share costs.
Thanks!!!
(btw, my project page, sightly outdated: www.fransedano.net (http://www.fransedano.net))
Quote from: 727737Nut on September 20, 2011, 03:28:16 PM
Follow along as I convert a customers real 737 throttle quadrant for use in his flight simulator. It will be fully motorized and offer the durability of REAL internal Boeing parts and select aftermarket parts to make it fully compatible with FSX.
Hi all,
A couple more pictures, got the servo's installed for the Spoiler Arm and Trim indicator. Any questions feel free to ask.
Rob
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Quote from: fsedano on October 28, 2011, 07:52:24 AM
Hi,
Your job looks fantastic!!! I'm going thru the same process, and I'm just stuck on how to remove the trim wheels. Can you post some pics / tips?
Also, I'm located in Switzerland, and I find difficult to find required mecanical pieces (motors, chain sprockets...) Would you have some pointers on where did you buy them? Maybe I can order online. I saw another colleague here on the forum from NL, maybe we could even order a batch of pieces and share costs.
Thanks!!!
(btw, my project page, sightly outdated: www.fransedano.net (http://www.fransedano.net))
[/quote
You can try Farnell.ch, that was where I got all my cockpit building parts when I was living in Switzerland.
Hi guys,
Trying also to convert a real 737 TQ, but stuck dismantling it. It seems it's not exactly same version as on these pics.
I'm stuck with removing central axis, the big nuts just rotate but they don't come off. Any ideas?
This is current state:
http://www.fransedano.net/?p=297 (http://www.fransedano.net/?p=297)
Any help is welcome ;-)
Did you try holding one while turning the other?
Yep - They are independent on each other. See
http://www.fransedano.net/?p=312 (http://www.fransedano.net/?p=312)
It's not one long axis, but two halves. As far as I see, for even changing the throttle cable everything must be dismantled? Can't be so difficult...
Did you try holding the inner tube while turning the outer nut? It looks like there 2 slots to keep the inner tube from turning while rotating the large outer nut. That tube is full width, trust me.
Hi Rob,
Great job on the TQ...simple and rugged but innovative.
For us newbies, is there any chance you could list the motors, stringpots, servos etc. that you used. The exact part number and supplier would be great. I know you are busy and I completely understand if you don't have time. I'm just starting to convert mine and I'm at a loss how to choose some of these without plain ol' trial and error. Of course, if someone already knows what works, I would rather go with that. Forgive me if this is listed elsewhere...I've searched and haven't found any particulars yet.
Thanks again for taking the time to post your conversion. It helps a great deal to a whole bunch of us!
Best regards,
Tim McNamara MD
Here are part numbers you need for the string pots and poly clutches.
http://unimeasure.com/ (http://unimeasure.com/) LX-PA-4.7 (this is the 4.7" string pot for
the flaps) LX-PA-10 for throttle levers
A&A Manufacturing 262-786-1500
Polyclutches Part# SAO20-8mm (note:8mm only if you get the motors I show you,
otherwise must match motor shaft diameter) you need 2 of them
Motors,
http://www.ebay.com/itm/Crouzet-Reversible-High-Torque-Gearhead-Motor-/160706868866?pt=LH_DefaultDomain_0&hash=item256ae03682 (http://www.ebay.com/itm/Crouzet-Reversible-High-Torque-Gearhead-Motor-/160706868866?pt=LH_DefaultDomain_0&hash=item256ae03682)
Thanks Rob,
This is very helpful. I appreciate you taking the time to put this together and it will be in one place for future reference!
Best Regards,
Tim
Where is the pricing for the pots? I always fear that when they aren't easy to find or not evident, they are way out of my price range.
They are 160.00 each unless you buy more than 5 or 6, can't remember
Great motors Rob!
Im using power window motors, similar, but one has a worn worm gear
and is really s#*@ing me :) I think Ill grab those
Thanks,
Nat
Rob
I recalled this excellent thread and as I have recently bought a real 737 throttle, I returned to the forum to reread it.
Sadly, I cannot access any of the attached pictures - keep getting the message "Sorry you are not allowed to view this file"
Trevor
Is this a forum issue or have I done something wrong?
Regards
David
Hi David,
I can't see them either, however I can repost pictures, and since this TQ is on my work table now (doing the interfacing) I can make you any picture you want. ;)
Nick
Nick
That is great, many thanks
I have PM`d you
Regards
David
Hi Nick,
I would greatly appreicate if you could re-post those pictures. I will be starting my conversion in the next few weeks. I am still researching and looking for the complete parts list.
Thanks,
Shawn
Here they are:
(https://www.cockpitbuilders.com/proxy.php?request=http%3A%2F%2Fi700.photobucket.com%2Falbums%2Fww8%2FOldElephant100%2F737NG%2FTQ%2FTQRob%2FTQ1_zps89b3c9dd.jpg&hash=d614700f4e3f7833cbacef7f9f8e389bf6a99bfd)
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(https://www.cockpitbuilders.com/proxy.php?request=http%3A%2F%2Fi700.photobucket.com%2Falbums%2Fww8%2FOldElephant100%2F737NG%2FTQ%2FTQRob%2FTQ8_zpsf00d32c0.jpg&hash=1c2203426e7560fa29666947557154758487b97b)
(https://www.cockpitbuilders.com/proxy.php?request=http%3A%2F%2Fi700.photobucket.com%2Falbums%2Fww8%2FOldElephant100%2F737NG%2FTQ%2FTQRob%2FTQ6_zps5bc12c5a.jpg&hash=aace89575e6167ee7f6675ed89828420ca06a6e8)
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I've given some thought to how I can make this request without sounding like a whiny worm or whatever, and haven't come up with much, so I'll just give it my best shot.
The thing is that this thread is of very intense interest to many of us -- note 11,000+ views! -- and it's such a pity that it got broken up and the pictures separated and some missing. Rob, I sincerely appreciate that you reposted most of the images after whatever happened happened, but I only see 14, far fewer than in the original thread.
I wonder if, in view of the very wide interest, one of the moderators would be willing to somehow reconstruct the thread, possibly making it a .pdf file that could be uploaded somewhere? Or, at a minimum, would you, Rob, please post the other photos? Sequence is not important; I'm pretty sure we could match them up to the text after the fact. In fact, if I had the photos, I could probably reconstruct it myself in the form of a Word document, and put it where ever y'all think would be good. Or I could just email it out on request. The main point is that the thread deserves to be seen in its entirety.
I suppose I'm especially sensitive to the missing photos at the moment because my TQ arrived last week, and I'm anxious to start breaking it down for a lot (!) of cleaning, light lubrication, and to start examining conversion options. But I'd much rather do that with some of Rob's vast experience, knowledge and wisdom behind me before I get too far into it.
Somewhat related, has anybody ever found any exploded parts diagrams or any other material that would help with this exercise?
Many thanks to Rob and the site hosts for making this thread -- and so many others -- possible. Fantastic hobby, fantastic online community!
...Dave
Dave Jones
Fort McCoy, Florida
Whether you think you can or think you can't, you're right. -- Henry Ford
Dave,
Thanks for the kind words. I will do my best to find the photo's tomorrow. I will update you the progress but please note I am on call this weekend for work so I may not get to it till sunday or monday.
Rob
Quote from: davjones on March 07, 2014, 03:12:41 PM
Somewhat related, has anybody ever found any exploded parts diagrams or any other material that would help with this exercise?
Its not for the full TQ, just the throttle section. The TQ is spread across several parts catalogs depending on the the system, so the trim, flaps and speed brake section is in the flight controls PM, park brake is in the Landing gear PM etc ...
This is for the 300-400-500 series
Rob,
Many thanks for your offer to hunt the missing photos. Please understand that there's no hurry for this. If you'd like, you can just send them to me and I'll re-assemble the thread. Least I can do! Then we'd just have to figure out where to put it, but as I said, I could just e-mail it to anybody on request. I think you probably already have my email from our earlier discussions. If not, let me know.
Mick,
That's a great help and I appreciate it. I understand perfectly what you mean about it being spread out -- a lot of different things come together at the TQ! As for it being from a 300/400/500, that's exactly what I want. Mine is from an early -300, and that's also the sim I propose to build.
Many thanks to both of you!
...Dave
Dave Jones
Fort McCoy, Florida USA
Rob -
Further to this TQ thread, did you have to drill a big mess of rivets to get the radio box separated? The only screws I see on mine are 10 at the upper front in front of the fire panel. Well, would be in front of the fire panel if I had one. :) Actually, considering how most of the screws are, drilling rivets might be just as easy...
I see there are several different varieties of these things, and mine is the only one I've seen that's most like yours. I'm almost sure this one's out on an early -300, though I've not been able to ID it positively...
...Dave
Dave
There are indeed several rivets that need drilled out. It goes quick since they are not steel rivets.
Rob
Yeah, I breathed easier when I saw that they're just aluminum. Tricky part will be to get a good punch mark right in the middle. What I didn't see at first was that there are also a bunch of nut plates that are riveted right through where the bottom of side covers attach.
Thanks for your lightning quick reply, Rob. Didn't want to start drilling till I was sure that there wasn't something else obvious that I missed. You're always a great help to all of us.
...Dave