Aerosim Solutions B737 cockpit rebuild

[Aerosim Solutions]

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!

I can't seem to make the pictures display here but they are in the Aerosim Solutions album!
Can anyone help with that?

http://www.cockpitbuilders.com/community/index.php?action=media;sa=album;in=21


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Cheers Gwyn
Aerosim Solutions

[jackpilot]

Very nice Gwyn, you are brave to build your own shell frame , not that it is difficult to make, but finding the right measurement and angles is, for sure!

If you want a full frame lower DU and do not use a working FO CDU here is a way with an EBay 12" monitor..(just in case.)

http://www.cockpitbuilders.com/community/index.php?topic=1088.msg8272#msg8272

and check same with new sim, scroll down  to reply#11

http://www.cockpitbuilders.com/community/index.php?topic=1738.msg13289#msg13289

[Trevor Hale]

Looks good Gwyn,

The reason your pictures didn't show here is your link is the the album, you will have to display the details of each picture and take the BBCode tag from each picture.  Place them in your message and bob's your uncle. 

(smg id=297) = only with [ brackets
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Chances are though if you uploaded them all at the same time, you can copy the code once, paste it and just increase the picture number each time you re-paste it.

Good luck with your project.

Trev

[Efe]

Whoa! Gwyn and Bob Reed... nephew and uncle... who'd have thought!?!

[XOrionFE]

Looks awesome Gwyn.  Beautiful work as usual.

Scott

[Aerosim Solutions]

Thanks Guys,

Trevor - Cheers for help with the pics, I'm making my trim wheels now so I'll try again with the pics of those when I have some ready.

Jack - The two FMCs are Flightdeck Solutions and I have a 10.5" touch screen mounted on it's side between them, I sized the box around these three components. Sim Avionics allows gauge rotation, I don't need the touch screen function but the monitor is a good size, I just 'cheated' the size of the square aperture from 170mm down to 166mm which is not really noticeable. You can see how the centre monitor just protrudes slightly which is actually an unintentional bonus - all the monitor controls are accessible. I'll tweek the throttle box to hide it and probably have a small lift off panel.

Now it's back to the TQ...

Cheers Gwyn

[hexpope]

Outstanding work. I just love the way you can access the monitor switch panel, by unscrewing part of the bezel, and @18kgs already. You`ll have to assign Heavy to your callsign

[Aerosim Solutions]

The trim wheels are taking shape, ten hours so far and probably another four to go. I might make a silicon mold of one before I paint them. I'm going to smooth out the joins with knifing putty to make it blend and look like it is one piece. I'm going to make the handle hinges tonight, more progress pics soon...
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Cheers Gwyn
Aerosim Solutions

[hexpope]

Making a mold out of them sounds like a good idea when you say they are going to take 14 hrs. Thats like nearly two days work, but their looking good.

[Aerosim Solutions]

A little more progress on the trim wheels with prep for painting!

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Cheers Gwyn

[Aerosim Solutions]

After a few dramas with the spray painting the trim wheels are finished. The first paint I used wouldn't harden and I had to get it all off and start from scratch, what a mess! The second time around I used a tough epoxy enamel, it took ten hours to dry but the result was worth the wait. Drawings are well advanced on the TQ's internals and that will be the next step.
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The wheels won't be going on the product list, I think they are in the too hard section!

Cheers Gwyn
Aerosim Solutions

[AK Mongo]

Glad to see it together Gwyn. I was awfully confused about what the handle did. It looked in previous pics like a worm gear.

Reid

[XOrionFE]

Incredible work Gwyn.   You are truly dedicated and amazing engineer.

Scott

[Aerosim Solutions]

Incredible work Gwyn.   You are truly dedicated and amazing engineer.

Scott

Thanks Scott, your comments are much appreciated! I think the best engineering skill here is the avoidance of sending five thousand bucks to Europe!!!

Cheers Gwyn
Aerosim Solutions

[Aerosim Solutions]

Hi all,
After about 25 hours of CAD design I've started on the new TQ at last. It has working autothrottle drives utilising clutch packs on the main axle, these clutches also provide the friction for manual operation. I think the clutch packs and A/T drives are a very viable stand alone product so they are earmarked for production and should benefit a few Boeing TQ builders in the near future.
I said on an earlier post that I wouldn't be producing 737 trim wheels but I take that back! A new partnership will mean I will have ten pairs available soon and they will be the cheapest on the market! More on this later. This is my new TQ so far...
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The next part of the TQ will be the trim indicator drive and trim potentiometer, the design I've come up with for this needs a set of bevel gears so I've made a tilting table for the fourth axis. I'm going to have a crack at bevel gears tonight. The TQ will have working trim and indication with 40 turns of the trim wheel total travel.
This is the tilting table on the CNC -
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More soon!

Cheers Gwyn
Aerosim Solutions

[Kennair]

I wish you'd stop doing this Gwyn, the more I see of your designs and construction the more I feel embarrassed about my own. Oh well I guess I just have to keep buying yours. Lol.

But seriously, fantastic work mate, look forward to seeing it in action.  Let me know when you'd like the website updated with all your latest inventions.

Ken.

[Aerosim Solutions]

Hi guys,
First of all how I envy you all being able to attend the get together at FDS, I'll be a certainty next time. I hope to see some pictures soon!!!
I kept going on the TQ and made some good progress over our long weekend. The fuel valves and switches are fitted, the autothrottle drives work nicely and I've started on the trim indicator drive train. These are the large white gears on the outside, the indicator pointers will be attached to these and they will be driven by the trim wheels. I am going to 'recycle' a Makita cordless drill motor and gearbox to spin the trim wheels, they are quite heavy and will need a strong motor with good torque. I've opted for IBL flap and spoiler lightplates from Simparts.de to save a bit of time and hope they arrive soon so I can start on the flap and spoiler levers.
More pics soon...

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Cheers Gwyn,
Aerosim Solutions

[XOrionFE]

Wow

That is looking amazing Gwyn.  I admire your patience and engineering skills.   Always a joy to watch something of yours come together.

Scott

[fsaviator]

I have to agree with Scott.  The rest of (minus the professional carpenters on the site) thrash around for weeks and splitting thumbs, gashing arms and heads, and almost putting out eyes with pointy objects...  then Gwyn posts his latest built from scratch creation.

Very nice work Gwyn.

[Kennair]

I have to agree with Scott.  The rest of (minus the professional carpenters on the site) thrash around for weeks and splitting thumbs, gashing arms and heads, and almost putting out eyes with pointy objects...  then Gwyn posts his latest built from scratch creation.

Very nice work Gwyn.

Let me give you another perspective.  I was peering into the workings of the throttle on Wednesday night while sharing a bourbon with Gwyn and I can tell you it's more impressive in the flesh.  You should witness the motorized throttle working and the simplicity with which it's built? Not to blow Gwyn's trumpet too much but its the simplicity that is his forte.  All his components are very modularized and can be broken down into components that anyone with a moderate ability could piece together and his generic modules achieve just that. 

On a side note I also had a fly of his single seat pit with Track IR..... COOL!  Needless to say I've ordered a racing seat off ebay and getting out my CH F16 flight stick and throttle in preparation for building mine.  A great way to keep flying while building.

Ken.

[Maurice]

Simply outstanding work!!! What more can one say?

Maurice

[Aerosim Solutions]

Cheers guys, much appreciated!!! More pics soon...

[Aerosim Solutions]

Hi all, some more pics of my TQ which is almost completed! It has auto throttle function, motorised trim wheels and speed brake, working trim indicators and a solenoid operated park brake lever. All labels apart from the fuel valve position will be backlit. This unit has my new trim wheels which are available as a product now. I haven't made the flip out crank handles yet but they will be fitted soon. The park brake light cap is a genuine Boeing unit, the first real part to grace my sim!
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Cheers Gwyn

[fsaviator]

 

Gwyn, you've outdone yourself now.  Outstanding!  Again...  I'm envious of your skills.

Warren

[Maurice]

All I can say is one word....WOW!!!!!

Maurice