Real 737 TQ conversion (updated 11/13)

[727737Nut]

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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[Trevor Hale]

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

[Boeing Skunk Works]

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?

[727737Nut]

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

[NeoMorph]

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. 

[727737Nut]

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.

[NeoMorph]

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!   

[727737Nut]

I have motors on the way for the lever's.  More pics soon.

[kondrat]

Hi Rob,

Your polyclutch.jpg is not loading for some reason. Can you check?

Thanks a lot,

Denis

[727737Nut]

Below are some pictures of the trim wheel motor installed and the Park Brake release actuator installed.

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[jackpilot]

Good work Rob...
Keep the pics coming..
Jack

[727737Nut]

Here are the Lever drive motors with the Polyclutch installed and #25 chain drive gear installed.

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[727737Nut]

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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[Flying_Fox]

Looks great, Rob! Amazing work!

[727737Nut]

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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[matta757]

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

[Flying_Fox]

The progress is unbelievable. 2 weeks ago it was just a dirty box and look at it now!

[XOrionFE]

Looks great Rob

Mine is next! 

Scott

[kondrat]

Thanks Rob for your progress pictures and information provided!

Great Job, very useful information. More pictures for motorized mechanism!

Thanks a lot,

Denis

[jackpilot]

Mine is next! 

Scott

Ha !!! 
(inside joke)

[727737Nut]

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 

[dnoize]

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

[727737Nut]

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

[727737Nut]

Got the lever drive motors installed today.  Waiting on the string -pots and custom pulley bracket to arrive.

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[ekznamu]

Rob,

nice work, where did you get the clutches ? I'm looking for them a long time.

Uwe