Version 4 (2009)

Built in late 2009. Plywood structure based on the Aker Barnes design, an impressive and clever idea with interlocking wood panels and no fasteners.

Switch Panels

The switch panels on the left and right consoles are my own custom designs. They were my first foray into designing switch panels and routing them on my homemade CNC. This project was actually why I built the CNC. The switches were read in by a combination of a Leo Bodnar USB board and some custom PCBs I designed and milled on my CNC. An evaluation board with a PIC16F84 and some code I wrote also did pulse generation for certain switches.

The switch panel construction technique is 1/8″ acrylic routed on the CNC, spray painted black, then text engraved with the CNC. Each panel has a two layer sandwich of acrylic. Backlit with white LEDs, then loaded with switches and stuff. I don’t have a laser table, but that would have probably been the easier way to go, especially for the text engraving.

Custom PCBs

I designed the diode interface PCB and the 12V distribution PCB both using Eagle (pre-Autodesk acquisition). I found a post processor online to generate g-code, then engraved them on my CNC. Engraving PCBs is not easy with a cheap-o homemade CNC. Definitely have to design for much larger spacings, flatten the spoil board, and manage cut depth. For the two-sided board, I milled a pocket in the spoil board to register it for flipping it over. Nowadays, I’ve since given JLCPCB.com a ton of business for both work and personal projects. I wouldn’t even consider CNC’ing a PCB like this again.

Early switch panel layout that was overhauled

Final switch panel layout but still missing elevator trim wheel

Other Components

Computer was a gaming PC I bought off Craigslist and a TripleHead2Go DVI unit to drive the three outside view monitors. That was a necessity since graphics cards were more primitive back then. 3840 x 1024 pixels total!

Off the shelf USB throttle and joystick – both eBay purchases! Scrap foam for cushions. Early model TrackIR for head tracking. ButtKicker bass shaker.

Fate

Overall a very good setup, but eventually new plans were afoot.

All of the switch panels were removed when this cockpit was decommissioned and they were transferred to its successor — checkout Flight Sim Version 5 for better pics in their final homes.