Boothcockpit: Build of the MIP Frame

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.