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I have started another site where you can discuss anything related to building a flight simulator cockpit. Check it out at http://flight-simulator-cockpits.com Common Cockpit Build Materials MDF(Medium Density Fiberboard) The most common build material for the general construction of a homebuilt flight deck is MDF or Medium Density Fiberboard. The smooth finish of this wood product can be painted to simulate the interior of a real cockpit. Below is a general description of MDF. Medium density fiberboard, or MDF, is a composite wood product similar to particle board. It's made out of wood waste fibers glued together with resin, heat, and pressure. MDF is appropriate for many applications, from cabinetry to molding, because it is smooth, uniform, and won't warp. MDF has many advantages over plank wood, particle board, or high density fiberboard. It's very smooth because the wood fibers used in its manufacture are uniform and fine. This makes it have low "tear out," which means that when sawed, the end has a smooth cut instead of a jagged edge. This also means that a coat of primer and a couple of coats of paint take well, leaving an attractive, finished surface unlike other composite wood products. MDF also has a mild reaction to moisture, meaning it won't warp or swell in high-humidity applications like a bathroom cabinet.
Plexi Glass Plexi-Glass can be used to fabricate realistic switch panels in your homebuilt cockpit. Using a band saw and a drill press you can easily develop custom fit panels. Plexi-glass is tough, scratch resistant and inexpensive. Using adhesive inkjet paper and clear plexi-glass you can create effective labels for your flight deck controls. And with some creativity you can create some effective backlighting. Good old Hans has effectively used this method, check it out HERE.
Electronics Of course at some point during your build you will need to fabricate electronic sub systems to fully integrate the controls on your flight deck. Highlighted below will be some of the electronic elements you will need to full integrate your cockpit. Wires & Cables The basic electronic element for your pit but it is the electron highway that will make your cockpit communicate. When connecting cables and wire make sure your connections are clean. Look up information on how to solder properly and crimping connections tight. I know it sounds basic but trust me I have had my issues with bad connections before. Think about what types of wire or cable will work the best for a particular application. Below are some types of cables and wires you might use: Connectors Getting all those wires together properly is going to take some good connectors. The advantage of having connections in your sim pit over just hardwiring everything, is it allows you a bridge between certain elements in your pit. Having connections at certain locations will allow you to perform repairs quickly and easily, also it will allow you to build a flight deck which can be taken apart and moved. D-Sub connections are the most common and come in different pin outs. Perf Boards Perf boards can be used when building custom cockpit controls. They allow you to solder connections, wires, and lighting. Perf boards can be cut to shape to fit into a panel and can be attached to a plex-glass panel using stand offs. Perf Boards can organize elements in a panel by allowing you to attach what is needed directly to it. Switches/ Potentiometers Switches and potentiometers are what bring control to a cockpit. It is important to have a basic understanding of how certain switches and potentiometers work, this will make sure you get the most out of the controls integrated into you cockpit. Below are some switches and potentiometers you might want to use in your homebuilt cockpit.
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Homebuilt Cockpit ...Build Materials
