B777 throttle quad build

[Westozy]

Hi all,

I will post progress pics of my B777 TQ build for Ken here!

I made the levers this weekend and attached them to the new generic TQ base.


3701
3700
3702
3703

Cheers, Gwyn
www.aerosimsolutions.com.au (http://www.aerosimsolutions.com.au)

[Kennair]

Simply stunning Gwyn! So glad to have my build showcase your new product line too.

Ken.

[Westozy]

Hi all,
I've made the flap lever mechanism for the TQ today and I'm really pleased with the smooth lift action. I will be offering this component as available as an individual 'generic' item! AUD$180 complete with both gears and a 10 kohm potentiometer...

http://www.mycockpit.org/photopost/data/692/B777-flap-lever-001.gif
http://www.mycockpit.org/photopost/data/692/B777-flap-lever-002.gif
Cheers Gwyn

[Westozy]

At the end of day six on Ken's TQ, I've fitted the reversers and knobs. It's now ready for buttons and wiring. I will be making the speedrake and trim levers followed by the housing. The plates already have the wiring tracks milled into them with the CNC so it should be easy to wire up.
http://www.mycockpit.org/photopost/data/692/B777-TQ-levers-003.gif
http://www.mycockpit.org/photopost/data/692/B777-TQ-levers-002.gif
http://www.mycockpit.org/photopost/data/692/B777-TQ-levers-001.gif

Every piece has been made on the CNC or lathe so far, I'm trying to build this quad without making anything by hand. That was the plan from the start and so far so good!

Gwyn
www.aerosimsolutions.com.au

[Anderson/SBSP]

Looks very nice!!! Congrats!!

[davek]

Excellent work as usual Gwyn

[Kennair]

OMG Gwyn those handles are salivation material!

I love the TOGA buttons too, how did you work out the mechanism for it?

Can't wait to grab this thing with both hands.

Ken.

[Westozy]

I love the TOGA buttons too, how did you work out the mechanism for it? FIGJAM!!!

Can't wait to grab this thing with both hands. I bet you say that to all the girls!

Ken.


Gwyn
www.aerosimsolutions.com.au

[Buddym]

Incredible! Don't you ever sleep? I always think to myself if this is what you put out as a "hobbyist", then your efforts on a professional level must be beyond belief.

Buddy

[Buddym]

Hey Gwyn, I've been meaning to ask you, how do merge the g-code from the gear cutting software with the rest of the code for the lever?

Thanks,
Buddy

Hi Buddy,

I use 'Involute' software to draw gears and save them as a .dxf file. I overlay the .dxf gear file on drawings I have made in VCarvePro5.5 and then delete the unwanted lines. Join all new vectors for creating the toolpath and VCarve generates th GCode.
To draw a gear in Involute only takes a couple of minutes, it is great software available here - http://delphusa.com/index.htm

.dxf files can also be opened with AutoCad and used in the same way but since I bought VCarve I have had no use for AutoCad anymore except for initial design work.

Cheers, Gwyn
www.aerosimsolutions.com.au

[Westozy]

Hey Gwyn, I've been meaning to ask you, how do merge the g-code from the gear cutting software with the rest of the code for the lever?

Thanks,
Buddy

Hi Buddy, cheers for your comments, I appreciate positive feedback from all members as any good LEO should!!! Hobbyist/Professional - the line has definately drawn closer! I have established a legal Australian business and I am being paid for my products so I am most definately professional now! However, I am still very much a passionate hobbyist and I really enjoy making simulator parts for myself or for others. The creative process is most enjoyable and I wish I could switch to fulltime at Aerosim.....one day I will!

Merging gear drawings to other drawings - I am using 'VCarvePro5.5' and 'Involute' software which makes it quite easy. I create the gear drawing in "Involute" which usually only takes a couple of minutes. 'Involute' allows you to save the gear file as a .DXF, I then open the .DXF in VCarve and it is there on the work piece ready to work with. For my throttle levers, I overlay the gear drawing on the lever drawing then just delete the unnwanted lines. There is one more step to join vectors and the gear teeth are merged with the lever.
The .DXF gear file can also be opened in AutoCad and can also be merged with AutoCad drawings, I have done this aswel but I have found that VCarvePro5.5 has eliminated the need for AutoCad as everything can be drawn in VCarve and it is much simpler than AutoCad.

Cheers Gwyn

[Westozy]

Hi all,
Some wiring pics...

TOGA and A/T disconnect wiring
3734

Reverser switch wiring
3735

Cheers Gwyn
ww.aerosimsolutions.com.au

[Buddym]

Ha! Didn't mean to imply that you or your products weren't professional, only that if your "hobbyist" activities produces these stunning throttles, I could only imagine what you do at your full-time job. Thanks for the info on the merging, that's how I would do it I was just curious how you did yours.

Cheers!

Buddy

[Westozy]

Hi all,
I'm back on Ken's throttle after making a few of the generic product range. I have mounted the generic throttle unit on a base plate and fitted the sides. The flapgate took a few hours to make as this one is machined on both sides from a single billet, I'm really pleased with the look of it. Last night I made the front and back covers but it got too dark for pictures - more soon.

3849
3850
3851
3852
3853
Every piece has been made on the CNC mill apart from the turned pieces. I really want to complete this one without handmade parts, it's getting there Ken!!!

Cheers Gwyn
www.aerosimsolutions.com.au

[Kennair]

You're a genius Gwyn, and constantly amaze me. Love those sides too. Now I just have to learn how to drive it! Just be careful with those throttle wires out the back while you're fitting it, they can damage easily :) Lol.

Cheers,

Ken.

[weshollett]

That is looking fantastic, will pop around shortly to have a look.

Wes

[Westozy]

Hi all,
Another hour on the CNC the fuel panel is ready for paint and engraving...
http://www.mycockpit.org/photopost/data/692/B777TQ-024.gif
http://www.mycockpit.org/photopost/data/692/B777TQ-025.gif

Cheers Gwyn
www.aerosimsolutions.com.au

[Westozy]

Hi all,
This weekend I've painted and engraved the fuel panel in grey as per Ken's requirements! I've added the 'generic' spring loaded flap lever which works great. The potentiometer drive has also been added. On the other side of the quad the speed brake lever and pot drive is installed, this has a large spring applying side loading for friction which is the same on the flap lever. Next I will be making the trim levers and when these are in place I will be able to start on the top covers and light plates to finish it off.
http://www.mycockpit.org/photopost/data/692/B777TQ-027.gif
http://www.mycockpit.org/photopost/data/692/B777TQ-0241.gif
http://www.mycockpit.org/photopost/data/692/B777TQ-0251.gif
http://www.mycockpit.org/photopost/data/692/B777TQ-026.gif
http://www.mycockpit.org/photopost/data/692/B777TQ-028.gif
Cheers Gwyn
www.aerosimsolutions.com.au

[Buddym]

Looks great man! I learn more just from looking at the photos of your work everyday.

Buddy

[Westozy]

Hi all,
I completed the trim levers and speedbrake this weekend. The trim handles were a nightmare to make but now I have patterns completed I am going to have a go at molding them later this week. I hope to announce the availablilty of the B777 TQ handles soon! Ken's TQ is mechanically complete and I just have to put the top covers and lightplates on. This one will be another one that will be hard to part with, at least I'll get to fly it, Ken lives about 10km away from me...
http://www.mycockpit.org/photopost/data/692/B777TQ-058.gif
http://www.mycockpit.org/photopost/data/692/B777TQ-059.gif
http://www.mycockpit.org/photopost/data/692/B777TQ-060.gif


Cheers, Gwyn
www.aerosimsolutions.com.au

[Kennair]

Great work Gwyn, just love those odd shaped trim handles. Cool centering mechanism too. There's some serious Bourbon for you at the end of this road! lol

Ken.

[Anderson/SBSP]

Another great work!! Congrats.

[jsfboat]

Awesome work! Keep up the great work, I bow before your skills and craftsmanship. Maybe after wards you can start working on 747 TQ stuff. :wink:

[Westozy]

Awesome work! Keep up the great work, I bow before your skills and craftsmanship. Maybe after wards you can start working on 747 TQ stuff. :wink:

Funny you should say that, I do plan to design and build a 747TQ prototype at some stage. There is a guy here in Perth (Greg H.) building a B747 sim, I organised building his frame and it's going to be a great sim.

Gwyn
www.aerosimsolutions.com.au

[Westozy]

Hi all,
I've finished all the mechanical parts now and it just needs to have the top covers and light plates fitted. I have made these and they are ready for painting so the end is near! I have stuck to my plan of making every component on the CNC so future production of the B777 TQ should be a lot easier. Hey Ken, I can almost taste the Wild Turkey already mate!
http://www.mycockpit.org/photopost/data/692/B777TQ-034.gif
http://www.mycockpit.org/photopost/data/692/B777TQ-035.gif
http://www.mycockpit.org/photopost/data/692/B777TQ-036.gif

Cheers Gwyn

[Kennair]

Excellent Gwyn, that looks great. Nice job on the trim handles too.

Can't wait to crack the bottle over it :)

Ken.