Building the 737 sidewalls

[vidarf]

Hi folks!

I've uploaded a PDF with drawings and schematics for the 737 sidewalls in the download area:
Downloads (http://www.mycockpit.org/forums/downloads.php) Cockpit Bitmaps and Drawings (http://www.mycockpit.org/forums/downloads.php?do=cat&id=42)
Misc. Flight Deck Drawings (http://www.mycockpit.org/forums/downloads.php?do=cat&id=48)
737 sidewalls

Could you guys check it and verify it for me as a quality control? I think it is going to be a great asset for future sim-nerds. Plus - by verifying it, I don't build the sidewalls to the wrong dimensions. :cool:

Appreciate your help!

[Goldmember]

We're also starting here. Capt. Kinsky and I will have a look tomorrow.

[choffmann]

Pretty much in accordance with the measurements I used. Looks ok.

Side note: Have you looked at this? http://737ng-info.blogspot.de/2011/03/sidewalls.html
Unfortunately only in german. But pictures say everything...

Cheers
Chris

[vidarf]

Yup, I've surfed that site a lot. :) And my design could easily be altered to look more like on that site. I don't know if all the extra stuff he does is really necessary. But to each his own, I guess...

[vidarf]

I've started the sidewall build:
Click to visit my website (http://fagerjord.org/index.php/737-cockpit-project/34-cockpit-related/78-cockpit-interior).

[Goldmember]

Hi Vidarf,

I like your idea of stitch and glue! Our idea here is to roughly make the walls out of MDF or plywood, then cover it with foam which we sculpt in detail to make very realistic interior lining. It should be possible to make all the curvatures, little recessed rooms, grooves etcetera. Then we cover it with fiberglass. Advantage is that you don't have to make a complex saw plan and wood construction. It will just be plane faces; the foam will be the finish. Just foam sheets that are used as insulation in house building. It seems one type of foam solves in the fiberglass and another type will hold but my buddy Kinsky (http://www.mycockpit.org/forums/member.php/5550-kinsky) knows all about that so I rely on him. He may seem lazy if you see how little he posts here but without him, the sim wouldn't be as far as it was now ;-)

Cue in, Kinsky! :-P

[NedHamilton]

Thanks for the detailed sidewall measurements. I don't think I've seen anything this detailed anywhere. And it's just in time for my starting the sidewalls.

Did you know there is a missing dimension?

It's in the pdf file on page 7 (the closeup of the table area). Just aft of the 0.174m horizontal dimension. Between that 0.174m dimension and the 45 degree, 0.075m bevel there is no dimension. And there is no way to "back-track" in the wider view on page 6 to get this dimension.

Any it's a minor point (I think it's about 200mm). Just thought you might want to add to the pdf file.

[vidarf]

The measurement for that part (the "table" top) is included in the PDF. Use the measurements on the plywood sheets. There are no missing measurements on those drawings - i just cut the first sheet using the document, and apart from a mishap with me not thinking straight, everything came out just right.

I will, however, upload an updated PDF. I forgot to include a drawing where all the parts are labeled on the sheets, so it is easier to identify each part.

Be aware that on several parts, the measurements are spread on the two identical parts. Some parts do not have any measurements at all; this means that they is an exact replica of the other part (remember - there's two of every part, one part per side).

The distance you refer to is 16.6 cm, but that measurement is not needed. The whole length from the front of the lighting panel back to the 45 degree part, is 34cm.

I will include a drawing of just the "table" top with measurements needed to easily cut the two pieces. I managed to cut the parts correctly, but that's just because I have the build process in my head. :)

Just ask if you encounter any more problems. That way, I can update the PDF so it is easier to follow.
I intend to share similar drawings on all the other parts I'm going to build. Why not? I am going to spend the time to draw it in 3D anyway, and if others can benefit from it - be my guest! :)
I got loads of help from the material Markuspilot.com and Ivar Hestnes has provided online, so this is me giving something back to the community.

If in your hobby you do care,
knowledge is so good to share!

:cool:

[vidarf]

Arjen, if you use Epoxy resin, the dense foam will work great. Usually pink or green in color here in Norway. Underground insulation.

You can actually "melt" the foam away from the fiber glass structure with Acetone. If you use 2 layers of woven glass fibre fabric, you should get a very sturdy construction. And you can easily epoxy "stringers" or stiffeners on the back side.

A new version of the document is uploaded (awaiting approval at the moment). Please download it and tell me what you think - is it useable or do I miss anything?

[JWS]

Vidarf,

Thanks for sharing your drawings. I've been looking around for information to make an EFB using a 10.4" TFT screen. I found different set ups, e.g. a screen placed vertical half way hanging down the side window. Another example is built in the sidewall. As far as I can tell, the 737 only has the "hang alone" version. Do you agree?

JWS

[vidarf]

Don't know. I've only found one image at Airliners.net, and that was from a BBJ:
http://www.airliners.net/photo/Royal-Jet/Boeing-737-7BC-BBJ/2060321/L/&sid=95bf715be28213c348bea2c81128c94e
A quick Google search for "737 EFB" only gave a few results, one of them here:
http://www.boeing.com/news/releases/2006/q3/060929d2_pr.html

The b737.org site has very little info and one single image near the end of this page:
http://www.b737.org.uk/flightinsts.htm

I'm thinking iPad in my cockpit. :) At least for some aspects, such as charts. But it is a long way to go before I run into that "issue". :)

[fsaviator]

Some info here:

http://www.boeing.com/commercial/aeromagazine/aero_23/EFB.pdf

and here:

http://www.boeing.com/commercial/flightops/efb_interactive/index.html

[vidarf]

Lots of progress has been made:

http://fagerjord.org/images/cockpit/thumbs/sidewalls/const_left_1.jpg (http://fagerjord.org/index.php/737-cockpit-project/34-cockpit-related/78-cockpit-interior?start=1)

(Click on the image for more details)

There is a small error in the plans; part 1 is too narrow. But with the stitch and glue approach, this is VERY easy to fix. More details at my website.
The above structure doesn't have a single nail or screw in it. Just plywood, glass fiber and epoxy resin! Strong enough to stand on!

[Westozy]

Thanks Vidarf, this is excellent info and much appreciated!
I intend to make the side panels and side windows on my cockpit into a one piece door on each side that will slide forward on rails to allow access to the cockpit. I was originally going to hinge them like a car door but I think that sliding the 'door' forwards and out of the way will be better especially if the cockpit is in a smaller room. This was actually my wife's idea, thank you Leonie! My frame is all steel so it should be an easy modification, meanwhile it's back to the TQ build!

Cheers Gwyn

[Goldmember]

This is a mockup we made, just to find out what would be a good construction. I think when we fill all the faces exept the windows, it should be a rigid construction.


http://youtu.be/p_Gk57Zmy3Y

To be able to access the sim easily in case of maintenance or other work, we make 2 wheels at the back and 2 handles at the front. That way we will be able to lift the windshield over the MIP and roll the shell backwards so the sim is in its bare state like it is now.

[birdyguy]

Thank you Vidarf ! Excellent information and great drawings. Thanks for sharing.

Ed

[vidarf]

LOTS of work, a few images:
my website (http://fagerjord.org/index.php/737-cockpit-project/34-cockpit-related/78-cockpit-interior?start=2)

http://fagerjord.org/images/cockpit/thumbs/sidewalls/sidewalls_last_fillet.jpg

[r55boy]

Vidar - quick question - i am kicking off a build shortly and have the luxury of being given permission by the wife to divide the garage in two, to create a dedicated and closed off space for the pit. The space i have is basically 8 feet long (front to back) by 7 feet wide, by 7 high.
I am planning a MIP from either cockpitsonic or SimToGo, so dont have final sizes yet. But what i cant quite get a handle on is the overall size with your side walls.
Do you have any sizes, or photos of where you are at with your build?
The plans for the side walls are superb - i am going to build a scaled mockup out of card in the next few weeks to verify how it all works before committing to the MDF order.
Thanks so much for your information and in advance for any extra advice.
Best regards

[NedHamilton]

Have you visited this site:

WWW.MARKUSPILOT.COM (http://www.MARKUSPILOT.COM)
there's a pdf on his site that gives every 737 cockpit dimension you'll need.
outer dimensions for a full size cockpit (without the nose cone and stopping at the circuit breaker panel) is 8 feet wide, 6 feet long and 6.5 feet tall. So the cockpit will fit in your garage but there won't be much room to work on the exterior.

[vidarf]

Should be about 240cm wide, based on the FDS MIP I have. Probably more in the neighborhood of 260cm. That's about 7.5 feet. Given your somewhat limited space, I would make the aft part of the 'pit a bit narrower. You won't be able to fit a true scale shell in there anyway, and definitely not side visuals. Get your mip first, then build around it. The side walls should be pretty far down on your priority list at this point.

When you get to the "side wall point", you might want to scale the plans a bit down in order to fit everything in your limited space. Absolutely doable, though.

[r55boy]

Thanks Vidar, good point on prioritisation. I do want side views though, but since the front of the pit is narrower than the back this should not be a problem right? The monitors will be sited I imagine just outside the windows, so within the overall rectangular footprint of the whole pit.

Certainly I need to get the mip dimensions before building the room to house it, I can see that now. So I need to get a handle on the space I need to site the monitors, outside the "windows", and what overall external dimensions this gives me

So my luxury of being able to build a room for this is actually a headache, as I need to set in stone my sizes before I have started construction...agh...

[r55boy]

Thanks Ned, I had seen that link but your sizes are really helpful. I need to think about monitor siting, access to upgrade in the future, and my aspiration to have an instructor station within that footprint will be hard to achieve...!

[Goldmember]

Photos: Boeing 737-7BC BBJ Aircraft Pictures | Airliners.net (http://www.airliners.net/photo/Royal-Jet/Boeing-737-7BC-BBJ/2060321/L/&sid=95bf715be28213c348bea2c81128c94e)


I must remember to buy no smoking signs.

[NedHamilton]

The other thing to consider is why bother with an outside shell. You will only be able to see one side of it with such small space.

My room is only 12 feet long and 10 feet wide. I actually started out with an external shell for my sim but ended up scrapping it because it would never be seen. I'm more interested in flying than looking at the outside. Besides having an outside shell makes it really difficult to do any work around and behind the MIP. I'm now completing a mini shell that's only as large as the inside of the cockpit and open at each end.

[Goldmember]

Still, the inner size between the aft windows is about 230 cm. Taking into account the inner shell gets wider below the window, the space is limited anyhow. Even if you only build the inside. And you do want to be able to work on the rear of the MIP, indeed. But also, if you want to service the inside of the glare wing, you'll need to be able to lift the top of it. That's something to consider as well. Haven't sorted that out yet but I think we'll make wheels under the platform so we can roll it from underneath the shell, maybe only 30-50cm would be enough.