Aerosim Solutions B737 simulator rebuild

[Westozy]

Hi all
Since the arrival of two beautiful Flight Management Computers from FDS on Christmas Eve, I have launched back into the rebuild of my simulator. I thought it might be a good idea to start a thread on it's revival as a few builders might want to follow the project as it unfolds. I will be using many of the products I offer for sale and it will be a chance to see how they are utilized. My sim has been stripped back to it's bare steel frame so I am more or less starting from scratch.
The first job was fitting new seat brackets to the framework, the seats will be 30mm higher than before and 75mm wider apart to allow for a bigger centre console. The next job was fitting the new control columns as seen here - http://www.youtube.com/watch?v=exL6H4yP8xc

Next on the agenda is a new set of rudder pedals and I've decided to make a set to save a few bucks, I'll post progress pics as the rebuild unfolds.
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Looks the part hey? More soon on the rebuild and as always feel free to copy!

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

[Wendy]

Hey Gwyn,

Very, very nice idea for making the pedals. Wonderfull.


Regards, Wendy

[Tony Hill]

Nice one, looking forward to seeing her revamped and in the flesh...

[Perik]

Nice, Gwyn

I'm using some PVC myself and just wonder if you have tested the strength - I mean how hard can you push the pedal without the foot-plate leaving the slots in the side support (I expect you have slotted in the plate) or do you have any support on the backside.
In a B767 I believe they talk about 60 lbs and a desperate pilot can push even harder as the end of
the runway getting too close too fast…. :shock:

Just curious - thanks for sharing and for sure this will be something to copy.;)

[Westozy]

Nice, Gwyn

I'm using some PVC myself and just wonder if you have tested the strength - I mean how hard can you push the pedal without the foot-plate leaving the slots in the side support (I expect you have slotted in the plate) or do you have any support on the backside.
In a B767 I believe they talk about 60 lbs and a desperate pilot can push even harder as the end of
the runway getting too close too fast…. :shock:


Just curious - thanks for sharing and for sure this will be something to copy.;)

Hi Perik, you have guessed how I did it! The pedal plate sits about 8mm back from the edge of the hoop section and I have glued some fillet pieces in place at the sides and up at the toe end. I use industrial strength cyanoacrylate glue on PVC which is just as strong as a PVC weld. BTW, PVC is quite easy to weld with the right welding sticks and a hot air gun. I'll post a pic of the rear of the pedal soon.
The main load will be on the grip with the grooves and this is basically a 50mm solid block drilled to 1/2" and it will pivot on a 1/2" stainless steel axle. The toe brake movement will only be rotating a potentiometer and the pedal is certainly strong enough, the PVC is heavier than it's aluminium counterpart!
I'm not sure about offering these as an Aerosim product, they take about two hours each to produce so sourcing real pedals still seems a better option at the moment to be honest! I have completed my rudder mechanism design and I will share it with our membership as the build progresses and I have new photos to display...
Anyhow, got to dash, getting married in 2hrs 7minutes, (dedication or what?)
Cheers Gwyn

[capetonian]

Well, .. Congratulations on the Marriage :)

[Polmer]

Wow... Love the footpedals!
Great job on those babies.

Polmer

[a340-th]

Anyhow, got to dash, getting married in 2hrs 7minutes, (dedication or what?)
Cheers Gwyn

Wow, Gwyn, astounding -

my heartfelt congratulations to you and the bride. Thinking about you both makes me feel good....

I do sincerely hope you will be thinking about a honeymoon in Thailand

Sent you some mails a while ago that went unanswered, am I on your spam-list ?

[737dragon]

I like your work..thx

[Westozy]

Thanks guys, here's some more pics of the rudders being built...
http://www.mycockpit.org/photopost/data/560/normal_01-Hoop-forming-tool.jpg
Tool for forming the rudder hoops
http://www.mycockpit.org/photopost/data/560/normal_02-Hoop-being-formed-after-.jpg
A warmed up hoop is 'stretched' into shape
http://www.mycockpit.org/photopost/data/560/normal_03-Completed-hoop.jpg
A hoop ready for assembly
http://www.mycockpit.org/photopost/data/560/normal_04-Hollow-axle-fitted-to-ho.jpg
The hollow axle glued into place
http://www.mycockpit.org/photopost/data/560/normal_10-Rear-of-completed-pedal-.jpg
Underside showing the fillet braces and the footplate that has been glued in and wrapped around the axle using a heat gun. The 6mm thick PVC becomes very flexible when it is heated up.
http://www.mycockpit.org/photopost/data/560/normal_11-Four-pedals-completed.jpg
Four sets completed
http://www.mycockpit.org/photopost/data/560/normal_12-Four-pedals-with-footres.jpg
Four sets of pedals and footrests

I'll be starting the mechanical components of the rudders next!

Cheers Gwyn

[Jordan Farmer]

Well Gwyn, I can see a new product for Aerosim :p Amazing work though, if only we were all that skilled :p

[Kennair]

You're a bloody genious Gwyn, fantastically simple too.

Ken.

[Westozy]

Hi all, a few more pics of this weeks progress...
http://www.mycockpit.org/photopost/data/560/Aerosim-Rudders-_19_.jpg
http://www.mycockpit.org/photopost/data/560/Aerosim-Rudders-_21_.jpg
http://www.mycockpit.org/photopost/data/560/Aerosim-Rudders-_22_.jpg
http://www.mycockpit.org/photopost/data/560/Aerosim-Rudders-_23_.jpg
http://www.mycockpit.org/photopost/data/560/Aerosim-Rudders-_25_.jpg

Another week should do it!

Cheers Gwyn
www.aerosimsolutions.com.au

[Westozy]

Hi guys, I've completed the rudder sets at last!
Well apart from a coat of paint but the mechanicals are done. The rudder pedals stay parallel as they travel over the arc and the return springs of good resistance and excellent self centering. The toe brakes have good travel with spring resistance and full analog braking capability via geared potentiometer drives. The centre box lid is hinged for easy access and it is held shut in the closed position with some small but powerful magnets. I'm really pleased with the outcome and I'm looking forward to installing them in the sim once the new floor has been fitted.
http://www.mycockpit.org/photopost/data/560/Internal_rudder_parts.jpg
These are the parts that make up the brakes and rudder linkages
http://www.mycockpit.org/photopost/data/560/Internal_mechanism.jpg
As always - KISS principle applied!
http://www.mycockpit.org/photopost/data/560/Brake_mechanism.jpg
The brake plate has the gear teeth for the pot and the return spring, this plate is fixed to the pedal
http://www.mycockpit.org/photopost/data/560/Toe_brake_potentiometer.jpg
The brake pots rotate 280 degrees so they should give smooth braking
http://www.mycockpit.org/photopost/data/560/Self_centering_springs.jpg
The spring and link arm hangs down on the pedal coming backwards and the other gets stretched
http://www.mycockpit.org/photopost/data/560/Hinged_lid.jpg
The lid opens for easy access
http://www.mycockpit.org/photopost/data/560/Rose_joint_link.jpg
This rose joint under the bell crank is for connecting to the second set of rudders
http://www.mycockpit.org/photopost/data/560/Two_sets_finished.jpg
70 hours later....

Cheers Gwyn
www.aerosimsolutions.com.au

[Kennair]

Once again, bloody amazing Gwyn. Simplicity is so beautiful and I love the easy access lid too, always thinking about maintenance hey :)

Cheers,

Ken.

[riche543]

bloody amazing Mr Gwyn, what more can i say. Nice 1. !!!!

[capetonian]

Wow, I feel like an absolute noob when I see your work!

[ian@737ng.co.uk]

Wow, I feel like an absolute noob when I see your work!

don't we all :o
one of the most talented chaps i've seen with his hands is our Gwyn.
well done matey :o
rgds

ian

[twisted8]

amazing work! thanks for sharing!

[npbosch]

Congratiolations Gwyn, thats is a very well made rudder. To make such complicated mechanical structure in one time, I think you designed it with someting like SolidWorks (or another 3D CAD program). If thats the case would you share the file with us?

[JWS]

Absolutely stunning. BTW, curious about the measurements.

JWS

[Matt Olieman]

As Always!!!!! AMAZING WORK Gwyn... WOW!!!!!!

Matt Olieman

[Westozy]

Hi guys and cheers for all the positive comments, always a buzz!
I really enjoyed designing and building these rudders, I did it in VCarvePro6 btw. I think the time it took to build them makes them unviable as a product, they would need to be priced at around AUD$1500 per set and Revolution already produce a similar set around this price. I am planning to develop the pedal plates as a seperate product, I have already had a few enquiries on these already. I'm thinking of releasing my plans and VCarve files with a tutorial if I ever get time to make one!!!
The rudder sets are sized to suit my own simulator frame, they are 450mm wide, 370mm high from floor to top of pedal and 490mm deep from the base plate to the back of the bell crank. They work extremely well and I hope to fit them to the frame this weekend, more pics soon if that happens.

Cheers Gwyn
www.aerosimsolutions.com.au

[Westozy]

Hi all, see a video of my pedal sets here...


http://www.youtube.com/watch?v=zqlS10I6tZc

Hope you like it!!
Cheers, Gwyn
www.aerosimsolutions.com.au

[Kennair]

Awesome end result Gwyn. If someone took upon themselves to mass produce your design they'd sell like hot cakes!

Cheers and thanks for sharing this,

Ken.

[Tony Hill]

VERY NICE!!!!! Can't wait to take them for a spin!

[jsfboat]

Gwyn, you have to make plans and a tutorial, this is just way to cool. I have have one pedal off a 757, but have wanted to use it to make a set. Please make the plans and a tutorial.

[Westozy]

Gwyn, you have to make plans and a tutorial, this is just way to cool. I have have one pedal off a 757, but have wanted to use it to make a set. Please make the plans and a tutorial.
Making plans and a tutorial is a huge task in itself, but as I have no plans to mass produce the rudder sets as a complete plug n play unit, I will make plans to share with the community when I find some time to do it! I do offer the pedals themselves as a stand alone product, they will be on my website soon.

Cheers Gwyn

[Westozy]

Hi all,
I have progressed a little more on the MIP this week which included a trip to Bunbury to fly Darryl's amazing Spitfire and deliver his latest part, cheers Darryl!
I removed the monitors from there casings and attached them to the back of my MIP with clamps made from PVC. The two outer monitors are 19" ACER X193HQ models and the centre monitor is a regular 17" LCD turned on it's side. The SimAvionics software allows gauge rotation and this monitor will display the EICAS, 3 standbys and the flaps gauge, I'm not sure if the yaw damper is modelled. Installing this monitor means there is no room for the autobrake switch to be fitted into it's own panel so I have mounted it off to the side and it will be driven by a trace wire cable - more on this later when I fit the cable.

http://www.mycockpit.org/photopost/data/560/B737-MIP-01.jpg
http://www.mycockpit.org/photopost/data/560/B737-MIP-02.jpg
http://www.mycockpit.org/photopost/data/560/B737-MIP-03.jpg
http://www.mycockpit.org/photopost/data/560/B737-MIP-04.jpg
http://www.mycockpit.org/photopost/data/560/B737-MIP-05.jpg

More soon,

Gwyn
Aerosim Solutions

[be3978]

Gwyn,
Can I ask what material the front panel is made from and what is its thickness.


Thanks.
shim

[Westozy]

Gwyn,
Can I ask what material the front panel is made from and what is its thickness.


Thanks.
shim

Hi Shim,
The panel is cut from 6mm Trovidur PVC, it will be primed and painted in epoxy enamel before mounting.
Cheers Gwyn

[Westozy]

Hi all,
At last I have cleared the backlog of orders and made another start on the Aerosim Solutions B737 simulator! I have just sold my old throttle and overhead so I thought I would start by making a new TQ. Here are the first pictures of TQ handle bodies, the backing plates that the lever handles attach to will be made from 3mm aluminium plate.
I'm not really planning to release a B737 TQ as a product as there are already so many available elswhere but I am thinking about releasing my VCarvePro CNC files at the end of this build when the set is completed for other CNC users. Stay tuned for more progress on the TQ build as it happens!!!
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Cheers Gwyn
Aerosim Solutions

[Westozy]

Gwyn,
Can I ask what material the front panel is made from and what is its thickness.


Thanks.
shim

Hi Shim,
I used 6mm Trovidur PVC sheeting for the MIP, it is great stuff to work with and quite strong!
Cheers GP

[riche543]

Like that idea of vcarve files nice !! keep us posted Gwyn

[Westozy]

Hi all,
More progress this week with the lever handles completed, I'll start design work on the housing next. I will be making molds for producing the engraved throttle knobs shortly!
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Cheers Gwyn
Aerosim Solutions

[Efe Cem Elci]

Hi Gwyn,
As I understand, there will be no physical limitation to pulling reversers while the throttle levers are not in idle, right? That's how I see it in the lever mechanisms at least...

[Westozy]

Hi Gwyn,
As I understand, there will be no physical limitation to pulling reversers while the throttle levers are not in idle, right? That's how I see it in the lever mechanisms at least...

Hi Efe,
Absolutely correct, a real TQ will not allow reverse to be activated unless the levers are in idle. I decided that a physical interlock is not neccessary for my own simulator as FS won't allow reverse higher than idle anyway and it would mean a lot of additional work. Whilst it would be great to have 100% accuracy in operation of all the components I make, I try not to lose sight that I am building parts for hobby simulators. When I make components for my own simulator I am also focussed on the fact that I might be developing a new product for Aerosim Solutions. Keeping cost and complexity to a minimum is high priority for me, (the KISS principle!) I will probably not release a B737 TQ as there are already so many available out there and the new FDS Jetmax unit looks such a winner, that would be my choice if I couldn't make one myself! I might however offer to sell components such as thrust levers, handles, TQ knobs, lightplates etc. I really like designing "make it easier" parts for the community and the variety of custom orders keeps it interesting. The "closed for trading" message on my website has only slowed business slightly and orders keep on coming despite the message! I will re open mid year bigger and better, hopefully with a switch to fulltime production!

Cheers Gwyn
Aerosim Solutions

[Westozy]

Hi all,
I made some good progress on the Boeing this week after catching up on customer orders. I made a full scale drawing of the side elevation of my sim frame in VCarvePro6.5 which made it a lot simpler to design the shape of the MIP stand. I still had to cut out the pieces by hand as the parts are too big for my CNC machine, I really need a bigger machine! I built the CDU bay/Mip stand out of 12mm PVC and 10mm white acrylic sheeting which made it a little on the heavy side but it sure is strong, the mip is around 18kg with the monitors fitted. The beautiful FDS Promax CDUs look fantastic in there, I will have to remove the Dzus fasteners and fit normal screws later and this will allow them to sit another 6mm lower in the apertures. The display monitor between the CDUs is a 10 1/2" touch screen I picked up on Ebay for $150, it was a little too long but this has turned into a fortunate positive, the monitor controls are just visible. When I make the TQ stand I will make a little access cover for the monitor buttons. If you look closely at the MIP you will see the three monitor controller card mounted in the lower part of the square bezels, this will make monitor adjustments a lot easier. I have made the hinged strips but haven't fitted them yet. The auto throttle motors have arrived so the TQ will be the next item on the 'to do' list!
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Cheers Gwyn
Aerosim Solutions

[fsaviator]

Gwyn,
you never cease to amaze me... It looks fantastic. I'm also building my new MIP right now and I thought it looked great but now:-(

I'm building out of sheet steel though. Fes' up, Gwyn, you have a PVC fairy down under, don't you? You must get great prices on PVC.

Seriously though, looks good. My CNC is down right now as I blew it up trying to wire in some proximity limit switches but I just got my new board and hope to be up and running soon.

Cheers!

[Westozy]

Cheers Warren, PVC fairy LOL! I do like working with PVC, it makes it easy to produce accurate parts with a good finish. The only downside is the weight because of it's density. My rudder sets are about 9kg and quite expensive to post.
Here is the result of the first 10 hours on the trim wheels, again fabricated from PVC!
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Cheers Gwyn
Aerosim Solutions

[Westozy]

These pics are how I assembled the discs...

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Three pieces that make up the main disc assembly
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Superglued and clamped to form the dish shape
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The conical disc for the centre hub, made from the offcuts of the rings glued together
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Machining the disc into shape, there are five parts glued together

Cheers Gwyn
Aerosim Solutions

[Westozy]

A little more progress on the trim wheels...
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Cheers Gwyn
Aerosim Solutions

[manhattan]

Hi Gwyn.

I see that you are sticking with the four red atc buttons on the yoke which relate to the default FS ATC system. You have used this method for some time, and I wonder if you have considered Vox ATC? I intend to do as you have done with my FS ATC as I feel that it is adequate enough.
Do you have sound seperation so that you only hear ATC through the headphones and the other sounds on speakers?

Love your work!

TONY, Plymouth UK

[Westozy]

Hi Gwyn.

I see that you are sticking with the four red atc buttons on the yoke which relate to the default FS ATC system. You have used this method for some time, and I wonder if you have considered Vox ATC? I intend to do as you have done with my FS ATC as I feel that it is adequate enough.
Do you have sound seperation so that you only hear ATC through the headphones and the other sounds on speakers?

Love your work!

TONY, Plymouth UK

Hi Tony,
The truth is I don't really use ATC all that much, on a rare occasion I'll have a go but I prefer to write an follow my own flight plans usually high altitude IFR. ATC complain too much when swoop down to beat up a nice looking valley in the 737!!!
My sim has been out of action for two years while the business has been growing but I am certainly enjoying getting back into it again. I finished the high gloss black on the trim wheels last night and tonight I'll be masking them up for the white visibility markers. The TQ handles are finished and work on the TQ housing can begin after the trim wheels are done. I've ordered all the parts to make the auto throttle clutches and drives, I'll be sharing this build and design as I don't intend to market B737TQs, there are already plenty available.
Cheers Gwyn

[Westozy]

Hi all,
After a few dramas with the spray painting the trim wheels are finished. The first paint I used wouldn't harden and I had to get it all off and start from scratch, what a mess! The second time around I used a tough epoxy enamel, it took ten hours to dry but the result was worth the wait. Drawings are well advanced on the TQ's internals and that will be the next step.
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The wheels won't be going on the product list, I think they are in the too hard section!

Cheers Gwyn
Aerosim Solutions

[Efe Cem Elci]

http://img832.imageshack.us/img832/2419/shutupandtakemymoneytn.jpg

No such thing as too hard! Just the "an arm and a limb and the life of my first born" category...

[No Longer Active]

I have deleted some threads here because as a moderator I believe it was the responsible thing to do. Should you have any further queries or criticisms then please feel contact me, this was done in respect of Gwyns thread. Thank you. Alex

[notgotaclue]

http://img832.imageshack.us/img832/2419/shutupandtakemymoneytn.jpg

No such thing as too hard! Just the "an arm and a limb and the life of my first born" category...

Genius.........

[vidarf]

The wheels looks awesome! But - how much do they weigh? If you are going to motorize them (even just for show), a big mass has a big momentum. Not easy to stop...

I have the Simparts TQ (not finished yet), and the resin wheels on that one are not that heavy. I plan to motorize them, but just for "show". A DC motor, a relay card and perhaps a switch activated by placing the flaps handle to zero flaps. The switch then switches between two voltages, simulating the different speeds on the trim wheels (faster when flaps are extended).

[Westozy]

The wheels looks awesome! But - how much do they weigh? If you are going to motorize them (even just for show), a big mass has a big momentum. Not easy to stop...

I have the Simparts TQ (not finished yet), and the resin wheels on that one are not that heavy. I plan to motorize them, but just for "show". A DC motor, a relay card and perhaps a switch activated by placing the flaps handle to zero flaps. The switch then switches between two voltages, simulating the different speeds on the trim wheels (faster when flaps are extended).

Hi Vidarf,

The trim wheels will be fully functional and driven by a 12VDC cordless drill motor with its own gearbox, it will also act as a brake when
de-energized, you are right they are quite heavy so I intend to use a soft belt drive which will reduce a shock load when the motor is activated. I fitted dual pole rocker switches to my yoke handles and one side of the switch will energize the trim motors through a pair of directional relays, the other side of the dual pole switch will be the back up trim that can be assigned to trim up trim down if there are any issues with the trim pot, (I had issues on my old PMDG set up where the trim pot operation was a bit vague.
I have just finished designing and 18:1 reduction gear train which will make the trim indicators work and also a 10 turn pot for trim adjustment. The CAD drawing is now up to about 30 hours but it is nearly completed, I just have to do the speedbrake drive and a few other minor parts. I'm really keen to start assembly. The levers are finished and I have the auto throttle motors and drives ready. I've "cheated" on the flap and speedbrake lightplates by ordering IBL panels from Simparts in Germany, these are 5VDC plug in units that will save some time for me.
The plan is to launch the beast this coming Christmas then I can re open Aerosim Solutions. I am planning to market the auto throttle drive I have designed for my own TQ, I think it will be a winner like the generic throttle base!

Cheers Gwyn
Aerosim Solutions

[Westozy]

I have deleted some threads here because as a moderator I believe it was the responsible thing to do. Should you have any further queries or criticisms then please feel contact me, this was done in respect of Gwyns thread. Thank you. Alex

Thanks Alex, you beat me too it!
I have moderator privelages on my forum and I was going to delete the posts that could have been perceived in the wrong way, I have spoken to Efe and no offence was taken but I would like my forum posts to stay with the subject matter and that is "Westozy's Mechanical Engineering". I share most of my designs openly to all, only the items destined to become products for Aerosim stay under wraps at this end. I do check in on my forum everyday and I appreciated the builders who jump in with valid solutions to questions asked. I would like to remind all uses of my forum that it is for discussing mechanical issues, there is not a lot I can help with in regard to software issues other than knowledge I have gained from experience. There does seem to be a high number of software questions asked here.
To all followers of my simulator rebuild, I thank you for your interest and I hope that you gain a few good tips along the way!

Cheers Gwyn
Aerosim Solutions

[vidarf]

This sounds VERY interesting! I have thought about a unit with motorization for the speed brake, trim wheels and auto throttle that could be fitted to any third-party quadrant. On my Simparts TQ, I could connect such a unit with rods to the different levers, and perhaps a belt (toothed, like in printers?) to the trim wheels. A PNP unit with everything built in, just apply power and a USB cable.

If this is what you have in mind, I would be VERY interested!

[Westozy]

Hi all,
After about 25 hours of CAD design I've started on the new TQ at last. It has working autothrottle drives utilising clutch packs on the main axle, these clutches also provide the friction for manual operation. I think the clutch packs and A/T drives are a very viable stand alone product so they are earmarked for production and should benefit a few Boeing TQ builders in the near future.
This is my new TQ so far...
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A new partnership for Aerosim Solutions will mean I will have ten pairs of B737 trim wheels available soon similar to the ones on my TQ, they will definately be the cheapest on the market. More on this later!!!

Cheers Gwyn
Aerosim Solutions

[Westozy]

Hi all,
I've made some more progress on the new TQ this week. The auto throttle drives and clutches work great and I'm really pleased with design. Having everything on the main axle keeps it compact and the clutches double up as friction devices for the levers in manual operation. I think these clutches and A/T drives will make a great product and I will release them next year. The two big white gears on the outside are for the trim indicators, they are linked with and idler shaft and small gears. The trim wheels will be powered to spin and it will have a working trim pot. It's quite a novelty to be making something for myself for a change!!!
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Cheers Gwyn
Aerosim Solutions

[Westozy]

Hi all, some more pics of my TQ which is almost completed! It has auto throttle function, motorised trim wheels and speed brake, working trim indicators and a solenoid operated park brake lever. All labels apart from the fuel valve position will be backlit. This unit has my new trim wheels which are available as a product now, I haven't worked out a price for them yet but they are available as seen in the photos or with an optional flip out crank handle. I haven't made the flip out crank handles yet but I'll get onto it soon. The park brake light cap is a genuine Boeing unit, the first real part to grace my sim. I am awaiting a pair of real eyebrow trims from AHPS to be able to redo the roof structure steel work.

http://www.mycockpit.org/photopost/data/584/Aerosim-Solutions-B737TQ-1.jpg

http://www.mycockpit.org/photopost/data/584/Aerosim-Solutions-B737TQ-2.jpg

http://www.mycockpit.org/photopost/data/584/Aerosim-Solutions-B737TQ-3.jpg

http://www.mycockpit.org/photopost/data/584/Aerosim-Solutions-B737TQ-4.gif

http://www.mycockpit.org/photopost/data/584/Aerosim-Solutions-B737TQ-5.gif

Another couple of weeks and I should have all the top covers made, it's getting really exciting! I ordered my radio console panels from Geremy at GLB Flight Products in order to save some time and I must say that the quality of his work is outstanding and highly recommended. The panels compliment the Open Cockpits radio modules perfectly, thanks Gez!

Cheers Gwyn

[Westozy]

More progress pics from the last two weeks...

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I still have to make and fit the trim indicator covers and labels, park brake switch and solenoid, LED lighting, wiring and paint. Not too much longer!

Cheers Gwyn

[Joe Lavery]

Hi Gwyn,

The image links don't work mate... :|

Cheers
Joe.

[Westozy]

Hi Gwyn,

The image links don't work mate... :|

Cheers
Joe.

Fixed I think!!!
cheers Gwyn

[zqzzd]

Hi all,
At last I have cleared the backlog of orders and made another start on the Aerosim Solutions B737 simulator! I have just sold my old throttle and overhead so I thought I would start by making a new TQ. Here are the first pictures of TQ handle bodies, the backing plates that the lever handles attach to will be made from 3mm aluminium plate.
I'm not really planning to release a B737 TQ as a product as there are already so many available elswhere but I am thinking about releasing my VCarvePro CNC files at the end of this build when the set is completed for other CNC users. Stay tuned for more progress on the TQ build as it happens!!!
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6046
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6048



Cheers Gwyn
Aerosim Solutions

hi Gwyn,
have you released the CNC files? how can i get it?

thanks

[Westozy]

hi Gwyn,
have you released the CNC files? how can i get it?

thanks

Hi there, no decision has been made as yet with regard to releasing my TQ as a product or releasing the CNC files. It depends on the cost of manufacturing the TQs in China. If it appears unviable, I will probably produce a project book with a DVD for home builders. The CNC files still need some work so that they accurately capture all the additions and alterations that occurred during the build and when the unit has been completed, I will have to dismantle it for wiring, painting and lubrication. When it is in pieces at this time, I will revise and update all the CNC files that have been produced in Vectric VCarvePro6.5

Cheers Gwyn

[Westozy]

Hi all,
I received a request to build a B737 tiller mechanism for Nic D in Tasmania. Nic sent me his real tiller handle and I took on the job because I will be needing two for my sim, the lucky F.O. will be getting one too! The unit has got an over driven geared potentiometer for good resolution and very positive self centering mechanism. I ordered a real tiller handle from APHS and I was lucky enough to be given a second real handle from a local customer, cheers Derek! I will try to reduce the size a little for the production unit and I hope to make these available as a product when Aerosim Solutions re opens next year.

Cheers Gwyn

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[Matt Olieman]

Looks fantastic Gwyn, as usual your work is amazing.

Matt Olieman

[Westozy]

I'm back onto the Aerosim 737 again and recently bought some great new seats. I scored a whole interior of a Nissan R33 Skyline coupe in 'Boeing grey' velour. I can't really justify the money it takes to get real seats into Australia so I will do a conversion of these car seats which started with modifying the seat cushions.

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More soon on the seat conversions...
Cheers Gwyn

PS I have asked Matt to resolve the issue with the picture attachments! They should appear soon!

[Geremy Britton]

Fantastic work Gwyn - as usual...

[Westozy]

With all customer requests on hold I made some good progress on the radio panel this week. The radios are from Open Cockpits, some panels from Geremy at GLB and the rest coming from my machine. I hope to make the console this week.
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Cheers Gwyn

[Joe Lavery]

Attachments don't work Gwyn, and thanks for the recommend.... :-)

Joe.

[OmniAtlas]

Hi Gwyn, invalid attachments.

I always like to see your work! Amazing stuff.

[Westozy]

Sorry guys, I've emailed Matt for some help, I don't seem to be able to post pictures at all. If I click on the attachments they open fine here. Matt has fixed my previous recent posts but we will sort it out soon. The radio box pics are in my gallery here - Westozy's 737NG - Mycockpit Members Gallery (http://www.mycockpit.org/photopost/showgallery.php?cat=560)

Cheers Gwyn

[Westozy]

Another test of uploading pictures...my sim at November 20, 2013
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Cheers Gwyn

[Westozy]

Hi all,
When I uploaded these pictures today I had a quick browse of some of my earlier stuff and it looks very dated. It also occurred to me that my "sim rebuild" is not a rebuild at all! The only thing I have recycled is the original steel base framework and even that has been heavily modified and increased to full scale. If I had known this four years ago I could have left my original sim together and sold it as a going concern! I've been a member here and sim builder for about eight years and I still love everyday I get to spend in the workshop, I have to apologize to all the customers that I have had to refuse recently, Aerosim Solutions is most definitely closed until my new Boeing 737 takes to the virtual skies sometime next year. I'm hoping another 6 months should do it!!
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http://www.youtube.com/watch?v=V8rBkyOWLKI

Cheers Gwyn

[Westozy]

More progress with the addition of the new glareshield and lower panel backlighting this week!
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[Westozy]

Hi all,
This weekend I made some oxygen mask components for the sidewalls. The original plan was to machine a dummy cover but I got a little sidetracked and ended up making opening doors for the mask box and a pair of masks. The panel has a functioning test button that I hope to interface to a sound file. My buddy Frank Cooper says it can be done and that will be a neat gimmick when going through the checklists! It has also been suggested that I connect the braided mask hoses to a keg, what a great idea!!
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Cheers Gwyn

[Shawn]

Hi Gwynn, take a look at http://soundplant.org I use this to assign key presses to a certain sound file and then use FSUIPC to map the button to that key. Works great, hides in the background and the basic version is free.

Shawn

[Westozy]

Hi Gwynn, take a look at http://soundplant.org I use this to assign key presses to a certain sound file and then use FSUIPC to map the button to that key. Works great, hides in the background and the basic version is free.

Shawn

That's great Shawn, cheers mate, Gwyn

[Westozy]

Hi all, after four long years my sim came to life this week with the new PCs and software in action. I still have to build the side boxes and upper structure for the nearly completed overhead panel so the push is now on to finish so I can restart Aerosim Solutions trading. I've just put a video of the Prosim set up running up on Youtube... I will do a better one when time permits. Last night I got the CPFlight MCP and EFIS units fully operational but managed to knock out two of the Opencockpits radio units. Such is life commissioning a new sim!
https://www.youtube.com/watch?v=QCDeLQIopJ8&feature=youtu.be
Cheers Gwyn

[OmniAtlas]

Hi Gwyn, when you resume trading will you be starting airbus parts production?

Regards,

Ben

[Westozy]

Hi Gwyn, when you resume trading will you be starting airbus parts production?

Regards,

Ben

Hi Ben,
One product I have already started work on is Airbus sidestick controllers. I have the patterns for the handles and I have designed a centering mechanism but that's about it for now. Panels are not a problem but I don't think I will be doing anymore TQs

Cheers Gwyn

[fsaviator]

Excellent work as always, Gwyn

[riche543]

Hi all,
This weekend I made some oxygen mask components for the sidewalls. The original plan was to machine a dummy cover but I got a little sidetracked and ended up making opening doors for the mask box and a pair of masks. The panel has a functioning test button that I hope to interface to a sound file. My buddy Frank Cooper says it can be done and that will be a neat gimmick when going through the checklists! It has also been suggested that I connect the braided mask hoses to a keg, what a great idea!!
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Cheers Gwyn

Its all looking great Gwyn, Will you be able to choose the type of beer you want with a switch next to the mask???..been busy over ere with a friend , doing his 737 its been 4 yrs in the making , were getting very close, He is not a member here , that's why we haven't seen any of the build , but its gunna be a good un i think. He is hoping to get it approved for training purposes, which will be tough but he has one amazing 737 sim soon to be up & running hopefully , it will be a long time coming. :-)

[manhattan]

∑강서건마≪Opyo01.CoM≫ 【오피요】 へ계양오피↖용인오피→산본오피 ∑강서건마≪Opyo01.CoM≫ 【오피요】 へ계양오피↖용인오피→산본오피 ∑강서건마≪Opyo01.CoM≫ 【오피요】 へ계양오피↖용인오피→산본오피 ∑강서건마≪Opyo01.CoM≫ 【오피요】 へ계양오피↖용인오피→산본오피 ∑강서건마≪Opyo01.CoM≫ 【오피요】 へ계양오피↖용인오피→산본오피

Hi Ingrid.

I cannot read your post? Seems to be in a foreign language?

Sorry.

Tony.

[Fess_ter]

He's a spammer. Run it thru google translate, still doesn't make much since. He has posted the same stuff 40 times.

[Westozy]

A giant leap the new projection system! https://www.youtube.com/watch?v=YNAh5N_eGkA&feature=youtu.be

Cheers Gwyn

[Joe Lavery]

A giant leap the new projection system! https://www.youtube.com/watch?v=YNAh5N_eGkA&feature=youtu.be

Cheers Gwyn

I don't know what you're getting so excited about Gwyn, it's only bloody awesome.... :lol: ;)

All the best mate,
Joe.