Switches, Switches and More Switches

It's been a while since I did my last blog, as you can appreciate having a young family and full time job doesn't leave much time for hobbies. But fear not I have been making some progress and now have all the switches wired and attached to the MIP.

I have't connected them to the controller cards yet as I will wait to mount the MIP onto the base structure before I do that, but all switches are now attached. 

Below are a couple of pictures and details of the switch types I used. 

This is what the MIP looks like now, lot of wires connected connected to the switches. I haven't mounted the display frames, LED and annunciators yet.

For the Nose Wheel Steering switch I used a Heavy Duty Toggle Flick Switch 12V ON/OFF Car Dash Light Metal 12 Volt DPST. This can be bought from Amazon for £2.39 Click Here

For the main and lower panel display unit switches I used 45 degree rotary switch  (Click Here) and BOEING 737 REPLICA KNOB STYLE 1 (Click Here)

Again for the rotary knobs (N1 Set, Speed Ref and Auto Break) I used the 45 degree rotary switches listed about.  I also used one Mini On/Off/On Toggle Switch Miniature SPDT which can be found here on Amazon: Click Here

Finally on this panel I order the flaps gauge from CockpitSimParts found Here

Much is the same for the right hand part of the panel, again have used 45 degree rotary switch and Boeing style knobs from flightsimparts, who make some really good stuff by the way.

My advise for the wiring of the switches, definitely get yourself a good wire stripper and crimper, I use this one and it is really does the job well: Stanley FMHT0-96230 FatMax Wire Stripping Plier

Also these female connectors come in really handy for connecting the wires to the switch connectors. You can solder them but for the moment because I am going to be moving this panel around quite a bit I am going to stick with this removable connectors. They are easy to crimp and simple to attach and remove as required.

RED 2.8mm FEMALE SPADE CRIMP TERMINAL CONNECTORS

Here are a couple of pictures of the connectors.

Next things I need to focus on:

• Attaching the LED lights 
• Make landing gear lever 
• Wire up to IO cards and test
• Mount of cockpit structure
• Move house to allow all the above

Build of the MIP Frame - Stage 1

Build of the MIP Frame - Stage 1

So I have made a start building my Boeing 737 cockpit main instrument panel, has only taken 4 moths to get the frame build :). 

From all the reading I've done on blogs and forums, this is probably the best place to start as a lot of the other component will end up fitting around the MIP, so best to start by making it first.

I have decided to go for the full size one, can't really fit this in my house at the moment but figure that I will get a bigger house in the next couple of years so why start small :)

I started by printing out a life size cutout of the main instrument panel using my laser A4 printer. To download the image click here. 

After you have downloaded the image, download a piece of software called POSTERIZA.EXE which allows you to create a poster out of A4 paper by stitching it together. The key thing when using this software is to make sure the scaling is setup correctly. I think when I did mine, I used 9x3 vertical pages. The easy way to check is by printing the first couple of outer pages off and checking that the ruler marks are accurate (i.e. that 1 cm is actually 1cm).

Once printed, cut each of the sections out and stick together with sellotape. 

I have only cutout the main screens at this point, I will do the remaining instruments and switch panels when I have cut the main board.

I marked out the template of the MIP onto 6mm MDF board I picked up from my local DIY store.

Once marked out, I pulled out the jigsaw and started cutting, with the results shown before. One thing I would advise, get a good jigsaw with the right blades. This makes a massive difference in the cut quality and accuracy, and will be something you will use a lot in the construction of a home built cockpit.

Now that the main board it cut out, I decided to order the Boeing 737 MIP panel kit from FlightSimulatorParts. This kit basically provides you with all the panels that you need to mount on the MIP before attaching the switches and gauges. I went for the 5mm thick panels as these are more realistic of the actual plane.

When they arrived, I laid all the panels out on the MIP board and used them to mark out the remaining sections of the board that I needed to cut or drill for the gauges and switches.

After completing the cut I attached all the panels and marked out where I needed to sand down the edges to ensure they fit tightly. I used coarse sandpaper for the faces and a wood file for inside gauge windows.

After I completed sanding down the frame I cleaned the MDF from any dirt or sawdust and applied a coat of MDF primer. This is really important as MDF absorbs paint and will leave you with a uneven and rubbish finish if you don't apply this. I applied one coat and then sanded down the face of the frame with fine sand paper to ensure a smooth surface. 

After the primer paint dried I proceed by applying the main coat of Iron Grey RAL 7011 paint. I got this from B&Q where they will make up any colour of paint as long as you have a sample for them to scan. I took in one of the switch panels and they managed to get a 99% exact match. 

I applied two coats to the MDF. 

After painting the main MIP frame I also spray painted the screw heads with some Iron Grey car paint from Halfords. 

Below is the finished product. I am pretty chuffed even if it has take ages to make.

 Next Steps

• Buy and attach switches
• Attach flight display frames
• Connect switches up to IO boards and start testing with FSX
• Buy flight display monitors and test fitting with MIP

Some Xmas Pressies

So I was a good boy this year and asked Santa Clause for some goodies to get my cockpit build off the ground, here is what I bought:

• Boeing 737 throttle, flaps and speed brake levers for the Saitek throttle quadrant (highly recommend) - FlightSimulatorParts
• I can't recommend these enough, feel really nice when flying the 737. You may have to tighten up the throttle quadrant though to make the levers a bit stiffer, otherwise they have a habbit of slides down under their own weight, couple of links below on how to do this
• Saitek Pro flight TQ weak Detent FIX
• Saitek loose levers SOLVED!
• BOEING 737 QUADRANT BOX - FlighSimPM
• AIRLINE TEMPLATES FOR MY QUADRANT BOXES - FlightSimPM
• PMDG 737
• If your going to build a 737 cockpit, this is probably the most realistic software you are going to get. I have had it 1 month now and am still trying to figure out the correct procedures. Don't let that put you off, it is perfectly easy to learn, just takes some time and effort vs the standard switch the engines on and fly
• GSX Ground Services
• Nice little add on that makes parking and departing the gate a bit more realistic

Boeing 737 throttle levers and box

My Current Setup

So before I begin building, this is what I currently have:

• Dell Precision T1650, 32GB RAM, Windows 7
• FSX
• Saitek Yoke
• Saitek Throttle Quadrant
• Saitek Switch Panel
• Saitek Trim Wheel

Not much to look at I know, but has done me well for the last few years and much of the equipment can be reused.

Hello

So I have finally decided to do it, build my own Boeing 737 cockpit. I have been a fight sim fan for ages now, all the way back to Fight Simulator 95, but now is the time to start building a physical version.

This blog has been setup to take you through my journey, successes and failures. I am on a budget so will be doing quite a bit of the build myself, which to be honest is half the fun. Obviously I will have to buy certain components and panels, but DIY all the way.

The plan is to try and document as much of the process as possible, so anyone reading this can replicate and hopefully improve on what I have done.

Let's get going.