Efe's Cessna 172 simulator

[Efe]

I recently decided to do away with my 737 cockpit and start work on a GA cockpit. It was partly because of space restrictions because I needed the space I was using in our factory to start work on my kit airplane but it also had to do with a change in my thoughts on flight training. Having recently weighed my options and decided to forego being an airline pilot to become a CFI, I thought this change would be ideal. This way, when I start flight training the sim will be a good place to get some familiarization and review time in.

So I was lucky enough to purchase some SimKits gauges, a yoke, a flaps lever, an ignition switch and some other small items to start off my cockpit. I haven't shared any pics yet as I want to get the panel cut and gauges etc. mounted so you're not looking at some stuff on a table. This morning I worked on the panel CAD drawings, working off the SimKits default provided on their site but also making the necessary modifications to make it more real. Their panel seems to be aimed at the desktop flight sim guy, as the trim wheel is located in the lower panel below the yoke and there is also a landing gear lever slot whereas mine will not initially have that.

Anyway since the CNC machine at the factory is always at my disposal, I can always get new panels cut as the sim develops or as I run into problems. Also, the SimKits CAD is a single piece, whereas their own complete flight deck product is made of multiple panels like the original. So I made some changes and I wanted to share it with you guys, perhaps you will have comments or some suggestions as to what I should change before having these cut.

Thanks...

https://rapidshare.com/files/3258227774/PANEL_C172_EFE.pdf

[XOrionFE]

Very nice job.  It will be great to see this come together Efe

Scott

[hexpope]

Your drawing are looking good on my side. Which type of CNC do you have access to at work ?

When do you think your going to cut, paint and show us the finished work on the main panel for your gauges?

I am also interested in your Kit plane that you are building, hows the progress on that level?

[Efe]

Thanks for the kind words guys.

I was at the factory this morning and boy was it a high point of the day for me. The machine we have there is a 3 axis CNC, local production with a Giordano Colombo head. I'll post a pic of it later as well as some technical specs (18000 rpm etc.). I don't have Autocad so I was using a freeware software to make changes so the designers had to make a few slight corrections to the drawing. For example, somehow I missed the top two notches on either side of the radio stack, and drawing the lines showed that they didn't align completely with the radio stack panel cutout so we shifted them slightly to get them to lign up correctly.

The day started off with me just hoping they wouldn't tell me it wasn't possible to cut the panel there, which would mean I would have to get to a laser shop and that just means more expenses. Once I was told that it wouldn't be a problem, we went about the job of picking material and finally decided on 2mm aluminium. The factory had pre-painted aluminium in white and red but I almost jumped in joy when the CNC operator asked me whether I wanted the panels painted.

I had always assumed I would have to paint them myself, and was actually thinking a location that would be well ventilated and where it would be OK for me to get paint everywhere. So this was the suprise of the day, learning that they could use the paintshop (with the move to the new factory, one of the biggest in city with over 500 sqm capacity) and have my panels painted. I decided on gray for the left and right side panels and black for the panel covering the cutout for the (currently absent) radio stack and lower panel. They will even paint the screw heads for the panels but I will have to paint the screw mounts (whatever the washer-like things between the panel screws and the panels are called) later as I have yet to get to buying/sourcing some.

Next step will be to make the structure for the panel, but I want to wait till I have the panels in hand and gauges mounted to see what kind of space I have to work with. I wouldn't want to make something only to discover that the gauges don't fit or that for some reason I will have to remake it.

[hexpope]

Thanks EFe for the info about the machines, I was interested to hear what they have at the factory. Sounds like you are really on your way with the cut out's and spray painting all been done for you. I hope it all works out for you. Keep us updated.

[Efe]

Thanks ninsurgent, I look forward to seeing what you have. The ELT switch I'm looking for is actually very simple and plain, just a square switch with ELT on one vertical side and AUTO on the other.

You can see a picture here, the switch is right above the Hobbs on the right hand side:


Doesn't have to be exact but I've seen some generic ones for light and experimental aircraft and they look like nitro switches for cars or emergency ballistic chute release switches. I want it simple and plain like the one above.

Hexpope, there are so many machines in the factory so I only described the CNC. We have a 6m aluminium cutter (called a guillotine locally, not sure whether it is the same in English workshop lingo), a industry grade bender (again not sure what its called) for curving steel and aluminium and many other tools. The factory is mainly producing pretty much every thing you can imagine for gas stations, save the pumps and subterranean fuel storage tanks. The canopy, canopy branding and covers, building branding and covers, totem (the big tall pole with the company logo), price panels, etc. so basivally everything. Apart from that we are doing exhibition stands, product display stands (what you see at the market) and signage as well.

You were also asking about the kitplane. I've started that project and currently we have a group of individuals that have expressed interest in it. My aim is to have joint ownership (distribution of costs, expenses, taxes, etc.) of the airplane once its complete. Currently we are looking into sources for aluminium as the plane we are looking at is a two seater completely aluminium build. Unfortunately the 6061-T6 aluminium that is used in kitplanes is not readily available in all sizes and thicknesses here and can only be produced on order and at high quantities at that. We are waiting to hear from a couple of companies and then decide what to do. If we can successfully complete this project and get the aircraft certified airworthy then I plan on taking it a step further and pitching it to university clubs and flying clubs around the country, whereby it will be much easier (And cheaper) to source the necessary aluminium due to the size of the order.

[Efe]

I actually got my panels back today at noon and quickly took some pics to put up but after putting them up in the other forum I realized I was already late for a lunch meeting on the other side of Istanbul and ran off without putting them up here.

There is a small mistake in the painting whereby they painted the whole right side of the panel black as opposed to the radio stack column and lower panel. Oh well, they didn't send me any painted screws so I would've had to go back anyway to get the screw painted. I almost make it sound like I'm not at the factory 3-4 times a week







I like how the 'grey' portions turned out as they used a metallic paint. Overall very pleased with the whole panel, and I will start mounting things and take some more pictures. Shame that I haven't had the time to sit down and work on the structure as I would really like to see these with gauges and put together.

As an added bonus, my package from Aircraft Spruce arrived just as I was shutting down the PC and leaving the office so I spent the good part of the journey wondering if the official (and apparently sent with airworthy certificates from the FAA!) Cessna split switches would fit in my modified-off-of-the-SimKits-example panel drawing. It fit like a glove, I couldn't have done it any better if I had the switches to measure while making the changes to the panel.