portable cockpit updates

[uzi_1984]

Hi all, thought id break out of the welcome forum and start a thread in here. Just too recap what im doing.

Im Building 2 matching boxes that are aprox 110mmX300mmX400mm each and will form the primary flight controls for a general aviation aircraft (mainly based on the cessna 152) The 1st box houses the yoke; light switches, master switch, ignition key and also a push too talk button (to use with VoxATC) and 2 knobs too adjust the altimeter and heading bug. The second box houses the throttle, mixture, carb heat, elevator trim, flaps switch, and radio controls. I've practically finished the yoke box, just needs a few finishing touches such as steel corners, and the graphics needs redoing. The throttle box ive only just started. Both boxes are interfaced too USB using Leo Bodners most excellent interface board.

heres some pics of the yoke box...


http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0270.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0275.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0274.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0272.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0271.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0268.jpg
http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0262.jpg
http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0269.jpg
http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0261.jpg

X axis pot
http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0265.jpg


Y axis Pot
http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0266.jpg


And heres sum pics of my progress so far with the throttle box. Ive turned the knobs and trim wheel on a lathe and undercoated them, theyre drying at the mo so no pics of those.

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0278-1.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0279-1.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0280.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0281.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0282.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0283.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0284.jpg

http://s40.photobucket.com/albums/e237/uzi_1984/yoke/100_0285.jpg

The shafts are precision round chrome plated stainless and are Uber hard lol! They slide in linear bearings, that are commonally used in CNC machines so very smooth and very tough. At the moment ive simply taped the shafts too the slide pots, coz like i said theyre so hard i couldnt even drill em, so untill i think of another way too fix em, the tape will have too do for now lol. The trim wheel fits onto that blue pot, which is a 10 turn pot so shuld be able too make very fine adjustments. Next stage is too fit the knobs, solder up all the connections and give it a try.

[steveeverson]

:roll:Really nice work indeed, very impressive, i wish i had your metalworking skills!
I can also agree that Leo Bodnars joystick cards are the business! - was just wondering what the extra circuit with the capacitors on was for?
steve

[uzi_1984]

Thanks:-D The extra circuit with the caps on is a toggle too momentary circuit that uses opto couplers. Basically it turns the on/off movment of the toggle switches into a single blip. Here's a diagram...

http://i40.photobucket.com/albums/e237/uzi_1984/yoke/toggleswitchcircuit.jpg

LOL at metalworking skills. I dont really have the proper tools or skills too work with metal. All the metal is 2mm sheet aluminum which is really nice too work with as its soft. When it comes too harder metals like steel, i really struggle as i have too cut em with a hacksaw and it takes ages. I shuld invest in some more tools really lol.

[magicaldr]

Very nice, have you wired all the points on the mag switch out of interest?

[uzi_1984]

yep each position of the key is wired and assigned too FSX (off, left, right, both, start) After hours of searching the net i couldnt find a key switch with 5 positions, so i 'made' one by stripping down a 2 pos key switch and fitting the output shaft too a rotary switch, each click of the rotary switch makes up the 5 positions.

[magicaldr]

Nice solution, I had the same issue until I got a Desktop Aviator panel which has a 5 position switch. However in their default panel only Off, Both, and Start is wired. I am planning to redo it myself at some point with all 5.

I bought it just before they launched the new one which has all 5 as wired as standard, always the way :roll:

[nricky]

Realy nice job in the stuff you have build. Great to see the pics in how you have done it. This will help a lot of people in building there own sim.

Great Job and great Pictures

Cheers
Norbert

[uzi_1984]

Hello all, time for the latest update.

I've fitted the roatary encoders too the yoke box and wired them all in. Theyre working fine but the trouble is it takes forever and a whole lotta turns too adjust the heading bug. Trouble is as you turn the encoder faster the pulses get narrower and narrower and FSX cant keep up with them and the heading bug actually starts moving slower. Has anyone got any solutions too fix this? prehaps sumone knows a way too program FSUIPC so that when u turn the encoder fast it sends the "increase heading bug quickly" command and when u turn it slow it sends the normal "increase heading bug" command.

As for the throttle box I've come on great guns with that and got all the controls working. Here's sum pics....

http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0287.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0288.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0289.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0290.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0291.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0293.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0294.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0295.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0296.jpg

All i got left too do now is skin the box, add the corners and finish off painting the knobs and trim wheel and fitting them.

[Matt Olieman]

Coming along real nice... thanks for the update. Love all that wiring :) :)

Thank you :)

Matt O.

[601]

prehaps sumone knows a way too program FSUIPC so that when u turn the encoder fast it sends the "increase heading bug quickly" command and when u turn it slow it sends the normal "increase heading bug" command.

This task can be solved using IOCards and SIOC from opencockpits.com
Yakov.

[uzi_1984]

Hello all. As promised some further updates....

I've basically finished the throttle box now, built the whole thing in under a week so im rather chuffed with that:D All it needs now is some rubber feet and the bottom needs painting. Check out the pics....

http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0302.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0301.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0300.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0299.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0298.jpg
http://i40.photobucket.com/albums/e237/uzi_1984/yoke/100_0297.jpg

The yoke box however is still not finished. Needs some kind of clamping system to keep it on the desk, havnt figured out how too do that yet lol; will keep you posted.

[Kennair]

Wow that's some fine engineering. You obviously work in the field. Considering how much companies like Simkits ask just for one C172 push-pull throttle I'd say you've saved a fortune. Have you considered going into business?

Ken.

[uzi_1984]

Wow thanks mate, thats a really nice comment:D (this is why i love forums lol) I'm actually a general builder by trade, and have always had an interest in mechanics and electronics. Im still not kitted out for metal working tho, the only true metal working tool i have is a pillar drill and a hacksaw lol! I seriously have mulled over trying too make a living out of this. I dunno if it's feasable tho, or if my skills are upto scratch. I would say tho the throttle box and yoke must have cost me around £400 too build, could build another set for a bit less; and a lot quicker tho. If i was too build and sell these id probably be looking for around £1200 for the set (throttle box + yoke) as they take a lot of time and effort. Just for a bit of "market research" lol! Would anyone be willing too pay that for these? would like too give it a go but i dont wanna build a load of yoke+throttle units and be stuck with them coz noone wants to buy em lol.