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My single seat Boeing 737NG at my favourite airport LOWI

2. Gen. Simulator  2017: News

Three Year ago I purchased one DC Motor Plus Card from Opencockpits. It was my plan to use it for motorize my old Throttle unit but first now after some small tests of the card I got courage enough to start the project at January this year.
It has been 3 month with a lot of work and many troubles and without any flight hours in my logbook.
The manual to the card is good but it tells not every thing and for long time I had great problems with USB disconnection. OC support told me to connect pin 1 and 2 on unused analog inputs and to remove the noise damping capacitors between motor connector and motor housing. This solved many of the disconnect problems but still with 4 motors connected it was not fully stable.
The card is only rated for 2A and it is for the total numbers of motors so maybe my motors are to powerful. With 2 motors it works fine and my Trim- and Spoiler Motor are instead of controlled by relays as before.
All the Throttle potentiometers are configured and calibrated in Prosim Levers config. You need also a  little SIOC script with only  3 inputs from Prosim ( AT power ON gate - Lever 1 and 2 servo output numerical ). Remember the SIOC subroutine for reading the servo output more times/ sec. otherwise the levers dont move.
Until now I have only few flights with the updated Throttle but it seems to work well. I hope one day to  upload a little video showing how nice and steady the levers are moving.

You can read more under Throttle Quadrant and Electronics- PC- software etc.
 

Future projects:  Aft OH-panel and J-rails for my pilot seat.

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1.Gen. Simulator at August 2007
I have used MS Flight simulator since 1995. My Boeing 737 Simulator Project was started up 2006 with cockpit seat, controls and throttle levers. The controls were connected to my joystick by cables. All was placed on a base facing my old desktop computer.
In this simple and inexpensive simulator I have had many good flights until I changed over to a for me more complex simulator technique in 2009.

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Seat
Pilot seat was the very first part of my Flight Simulator Project (2006)

Dec 2012: Seat rebuilt to NG-style with headrest. On the same time the back rest has become adjustable.



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Flight Controls
Rebuild in the winter 2008-09 with potentiometers instead of my old joystick by cable solution.

Dec 2011: Nose wheel steering is working. It is now possible to handle the plane on ground at low speed (below 45 knots IAS) by the tiller in left side. Above 45 knots only the pedals is working.

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Throttle Quadrant
Build winter 2007-08. Electric wired and connected with computer 2009

Mar. 2014: After running ProSim the trim wheels also are working when flying with autopilot engaged. My noisy trim motor (Bosh accu drill machine) is therefore replaced by a small silent gear motor.
Apr. 2017:
 News  Throttle Levers motorized with DC Motor Plus Card from Opencockpits. Trim Wheel transmission  changed to gear belt instead of a chain. If not armed Spoiler now also deploy when reverser lever is moved and will be stowed again when throttle lever is moved forward. Reverser changed from switch to potentiometer control. Parking brake now with release solenoid. You need to use toe brake before set and release parking brake lever.

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OH- Panel
Engine Start- and light panel build in winter 2008-09. Feature: Electric Engine Starter switch cut out
Rest of the FWD OH-Panel inclusive instruments is built winter 2010-11.

2014: OH-Panel now alive with ProSim and OC interface cards

2015: Engine Start Switch now with push before turn function. Also new YAW-Damper and Wing Anti Ice switch with electromagnetic hold.

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Main Instrument Panel
Landing Gear lever unit build in winter 2007-08.
Has been replaced by a new unit Jan 2015 (see below)

May 2012: Also for the MIP I have used acrylic. Base panel in 3mm sheet cut in one piece. The different panel sections are also in 3mm and at last the 3mm light panels (Opencockpits and some home made). Frames for monitors are made of MDF.  An alu-profile in top and a profile of wood in bottom give the panel stiffness.
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Landing Gear Handle
New handle with on ground lock and working lock override finished Jan 2015.

The unrealistic function of my old handle from 2008 has worried me for a long time so Dec 2014  construction of a new more realistic version was started up.
Now you need to pull the handle about 8 mm before it can be moved up or down. If the plane is on ground a lock prevent the handle to be moved. When the plane is in the air a solenoid release the lock and  you can move the handle and get the gear up. If the solenoid should fail you can pull  the red trigger and then pull the handle further 7 mm and override the lock .

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Pedestal Bay
Pedestal build in winter 2010-11.
Dec. 2013: Pedestal finished with VHF1-,NAV1-,ADF1- and ATC Modules from Opencockpits. Dummy radios and the other panels for the pedestal are also from OC.
April 2014: Cargo Fire and Trim panel now working with ProSim.
Nov. 2014: New working NAV2 module replace my NAV2 dummy 

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CDU-Bay
Mar. 2015: I purchased the FMC/CDU from Opencockpits. Some modifications of the CDU and the bay was necessary before the unit could fit in my old bay.
Frame for lower DU is ready.

Jan.2016: I purchased the CDU panel from Opencockpits for the 1. officers dummy CDU.

Mar.2016: An old 14" notebook monitor with a spec. LCD-controller board is now working as lower DU. 

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Engine Fire Panel
Engine Fire Panel build in winter 2010-11.

April 2014: Panel connected and it is now working fine with ProSim.

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Cockpit Lamps
Cockpit Lamp for the left Side Wall and another Lamp for the Eyebrow Window build in winter 2010-11

 

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Projector
Feb. 2011.  At last I got my projector. I have now the Cockpit View
on a 120x160cm screen in front of my Cockpit. What a different it has really improved the simulator. Some times my brain get cheated and I feel the cockpit is moving.

Mar. 2014: My old DVI - VGA cable between PC and projector is now replaced by a 5 meter DVI - HDMI cable (price10 ). This has improved the outside view quality a lot.

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Switches and knobs
June 2011: Many different switches and knobs are used in the simulator. Most of the switches are miniature (7mm) model modified with a self made turned handle in aluminium. The handle is glued to the switch and in fact the max. diameter is 5,6mm it is possible to mount and dismount the switch afterwards. The small and big white rubber caps I have got from Engravity.  The B737 standard knob is also from Engravity but special knobs I have made of wood.

See also my EFIS and MCP module (Opencockpits) with modified knobs and switch.

Dec. 2013: Self made special knobs for the Cargo fire panel, WX radar, Audio panels, Rudder trim and Cab. door lock panel are finished. I have also made new handles for the the four Landing light switches.
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Instruments
June 2011: 7 different gauges for the FWD-OH panel and a Flap Indicator are finished. Build in 3mm acryl and housing of 50mm PVC tube.  The needle is moved by a little RC servomotor directly or by by gear wheels if the movement has to be greater than 180 degrees or if a dual needle instrument. Gauge face is printed and the whole is covered by a 2 mm acryl glass.

May 2013: Yaw Damper and Brake Pressure gauge for the MIP are finished.
Jan. 2014: New dual needle pressure gauge.

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Various cockpit elements
Oxygen mask panel Oct. 2012
Fresh air panel Oct. 2012
Check board Oct. 2012
Left side wiper Oct. 2012
Magnetic standby compass is finished and now working Dec. 2013
iPAD tray Feb. 2014
New MAP-CHART light panel Feb. 2016

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Electronics- PC- software etc.
I use I/O Cards from Opencockpits. USB Expansions Card, Master Card, USB Axis Card, USB Servos Card, USB Stepper Card, Relays Card and Connector Cards for easy in-/output connections.
Programming software SIOC.
2014: System logic and Display Units now by ProSim 737 Suite
2014: New PC and software
2017: News  The new DC Motor card for the Throttle has caused some changes in the interface card layout.

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