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Simulator Design: cockpit enclosure This is the part that worries me the most! I'm not a fully-fledged handyman, but I get by with most jobs. Building structures from wood and metal is not something I've done alot of so I'm a little apprehensive but also looking forward to the challenge. I've looked at all sorts of alternatives for the framing of the base and shell. The main options are:
There are some good examples of these constructions by other builders (see the links page). The alternative I've selected is 'handy-angle' steel. Imagine a mechano construction set - you know those tiny metal strips with holes all the way along. Handy angle is an L-shaped form of that made from 2mm thick steel and 3 metres long. Much of the frame is constructed with bolted joins and little welding has been needed. Internally I'm using 18mm MDF timber sheets to build the main panel structure, CDU pedestal, avionics pedestal, and side units. 3mm MDF sheets will be used for internal linings. I'll be trying to save weight wherever possible. Externally I'm cladding the back section with 0.6mm aluminium sheet. The front section (nose) will not be externally clad to unsure no interference with the visual systems. Also - anyone who uses this sim will not get to see the front so it doesn't matter if it doesn't look like the real thing (remember this is a simulator, not an aircraft replica). Below are drafts of the plans for the enclosure. I've used a wide variety of sources to get the dimensions and so I've been a little nervous about getting it right. I may put all this into a proper CAD package down the track. Note: these JPG files are large (350-450k) and designed to fit on A3 paper. Right-click the link and select 'Save as...' to download the files. Update (02/12/06) - I've split the whole construction into two components to allow for moving. The split line is across the cockpit (left to right) - just in front of the jumpseat position. The forward section will now have a central steel frame made from 40mm square steel tube. This frame will form the backbone for the overhead panels and window centre post. Here are 3 diagrams which show the (draft) plans for this:
The following pictures provide views of what it's like to build with handy angle including various joins.
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