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Framing

The entire frame and platform was designed in AutoCad to assure all parts mated properly. The frame structure was print to scale on several pieces of paper to form a template. The template arcs were then laid over large sheets of MDF and traced.

Platform

The motion platform is mainly 2x8's, 2x4's, 3/4 plywood, and steel reinforcement anchors. The rudder pedals were a purchased commercial unit. Centering and feel is achieved by using several pulleys and a high tension spring.

Control Wheel

We purchased and installed a B757 control column from ACES Engineering in Canada. A very expensive purchase but one that provides altimate feel and functionality. This is a superb product and I would recommend to anyone building a high fidelity simulator.

Main Instrument Panel

A frame constructed from MDF was made to support the main instrument panel and rudder hub. Two 24 inch flatscreen monitors were later installed behind the various instruments.

Installation

Upon final positioning, the major cockpit components, main instrument panel, side wall, and pedestal, are affixed to the motion platform. As these items are modular, they will can be connected and disconnected if needed.

Fuselage

White fiberglass sheeting is used to form the exterior and interior fuselage. This makes for easy cleaning from time to time. Imagine the looks I received from neighbors.

Individual Panels

Every panel of the simulator was measured in a real 757, drawn in AutoCad, and exported to a high end laser cutter. Image above shows the panels being painted at the Delta hangar at CVG. Once the paint cured, each panel was later placed back into the original cut sheet and engraved.

Wiring

Once wired, each panel goes through a bench test to assure all indicators and switches are performing correctly. Following testing, each panel is then secured into the overhead panel bay.

Korry Switch Replicas

The switches that make up the panels were designed to mimic the Korry/Eaton switches used by Boeing in their indicator panels. Retail pricing for each switch exceeds $500.00 US Dollars. Therefore we had to design and manufacture our very own. Eleven individual parts were laser cut and assembled to make up the switch latching system. Similarly, all switch legends were also laser engraved and illuminated by low voltage LED lamps.

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