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.
01-Footrest-sides.jpg
02-Footrest-carcas.jpg
03-Footrests-ready.jpg
04-Making-footplate.jpg
05-First-prototype.jpg
Looks the part hey? More soon on the rebuild and as always feel free to copy!

Cheers Gwyn
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….

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….


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...

Tool for forming the rudder hoops

A warmed up hoop is 'stretched' into shape

A hoop ready for assembly

The hollow axle glued into place

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.

Four sets completed

Four sets of pedals and footrests

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

Cheers Gwyn