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Customized Overhead Support

Sometimes people don't want a complete shell inside their homes...

Then, which one is the best solution?, well, maybe reduce at minimum the size of things, and that is the case, because Alejandro, a Majorcan builder that I meet through a common friend, Jaime Homar, he ask me to modify, re-wire and configure an entire old cockpit that he bought to the family of a deceased good friend and builder, called Francisco Palazon.

This was the first custom part made for, a stand-alone support for his overhead.

sop ovh alex 1

This support has made with an iron rectangular profile, and his size is 60x30mm., that means is a very strong item, because the overhed isn't heavy itself, but being so upfront, the force that resists is much and we need to hold hard.

The second part of the support is the overhead support itself.

sop ovh alex 3

this part is assembled over the central profile and holded by some screws, that allow to disassembly when you need to do.

Also, the support have a system that allows to rotate the overhead, as the real one, to have access to the internal part of him for maintenance or reparation, configuration, etc...

As I said before, this part has made as a custom part, for this reason, it have this "strange" shape as you can see on the next picture, because in this way, we can avoid the lenght of the glareshield on the Front Panel assembly.

sop ovh alex 5

Next thing is to build a platform to raise a little throughout the whole front panel and add the seats, throttle and pedestal.

But first, I should re-wire the entire overhead, build the gauges, not so difficult as well, it'll connect to a good interface cards suite as Simioboard and configure it for use, I imagine that will be with some software suite as Prosim, although still not defined that point.

sop ovh alex 4

 

Well, I need only to wait a couple of days, because I need to finish before that some projects for some customers, as the linked control columns or a pair of rudder pedals, but as I say always: "this is another story..."

Thanks again for read this and see you soon.

Bye.

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First Project

Ok, our first job is on the oven...

Yeah! Tomas Molina, not only a customer, also a good friend, ordered us a Control Columns Linked System for a B-737, and motorized as well.

In fact all the parts are already assembled and welded, as the main frame and the link support. You can see it on the next images (some images, was took on the blacksmith facilities with my mobile phone, and quality aren't his best side :-)) , the first image is the main structure, where you can note the feet for adjustment, that allow to level the complete system to the main floor on the flightdeck, and adjust the height as well.

1st str closeup

And this is the complete main frame, supports were welded on the frame and all the holes was did.

1st structure

Each part was drawn previously and these plans, of course, are also used as a reference to make things as perfect as possible, to have on this mechanism less tolerances and in this way don't have issues on it.

lot of plans

This is the Link Support, there are a lot of little parts welded, because we need to have there installed all the tensioning system for the link, Roll Force Feedback system installed, bearings for the Roll mechanism, and a long etc...

link part

Ok, all parts joined, well, almost all... because this is only a simple test to confirm that all are working, next step, put the Yoke Wheel and his mechanism of transmission.

columns test

Upppsss!!! I forgot to show you some things that are already finished and painted. This picture shows you the Pitch Force Feedback mechanism (not motor assembled yet, only mechanical parts). This mechanism are ready to add to the main frame when it are painted and ready, maybe this happens the next week... I hope!!

force feedback 1

Another view of this mechanism.

The color? yes, after think about this a lot, I decided to make as on the real ones, use the famous "Green Zinc Chromate", well, or similar, on all the hidden parts of the mechanisms, not only in this project, on all the Boeing mechanisms that have any hidden parts, I don't know if really gives a pro image, but I'm pretty satisfied with this and my thought is to use always.

force feedback 2

More pictures, are you asking what's this?, well, some parts that are waiting to assemble to the main and link frames, motor support, roll pot support, feedback transmission, etc...

waiting parts

Can you imagine this?, look the next picture...

linked yokes parts

Yes, yes, this is an example of the total amount of different parts that we need to finish this system... I know, I know, most parts are simple gear, or chains, etc.., but when you take a look to this picture, maybe you could imagine how my brain is burning.

Ok, blacksmith still working, not on this project but yes on next projects... as the rudder pedals, single control column, etc, etc, etc...

welding support

Ok, this is all for today, thanks for read this, and we will follow with more information.

See you soon.

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Shell plans for B-737

MODIFIED TO CLARIFY SOME MEASURES AND ANNOTATIONS

Time ago I made some drawings to my friends on the spanish builder forum.

Now I've translated these plans in english and made some modifications. If you are interested on it, please register and download this file.

B737 SHELL Pgina 01     B737 SHELL Pgina 05

Two examples of these drawings.

I think is an interesting file, because allow you to build a simple structure for the flightdeck. It's designed using standard squared iron tube of 30x30mm. and everything welded, but if you want to make it with wood, isn't difficult to change to this material, is simply make it stronger adding some section (i.e. 30x40mm, or 30x50mm, etc..)

A "must have" on your library as a cockpit builder.

I hope you enjoy it.

Note: Click on the tittle or on the "Read More" button of this article to show the link

Simujabs Team.

 

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Restoring a B-737 Yoke

What's better than the real one?

This is what I thought about the yokes, for this reason I bought one from a retired 737-300 and I restored it, to have a perfect base to mould and replicate more units.
First step was disassemble all the stuff from the unit, removing the trim switch group, the A/P disconnect button and support, the microphone button assembly, the upper cover and finally the internal wires with his support as well.

Parts removed from the B-737 yoke

After that, I revised the yoke and as you can imagine, isn't a new item, it is completely scratched and damaged, there are some zones without paint, due the use of this control wheel, well, then it's time to sand all the yoke with an orbital sander, removing the first layer of the coat, leaving it the more perfect surface as I can.

Foto 12-04-13 10 30 50

Ok, I did it, now I need to put some putty on the little damages that this unit have, and then sand again, but this time I did by hand.

Next step was spray one thick layer of primer, the same that is used on the cars repairing, leaving a surface a bit rough, as you can see on this picture

First layer of putty, after first sanded

Ok, I did again, now the next step is to sand by hand, and obtain the best finished surface to receive the "almost" last layer of coat, on the picture isn't difficult to see the zones where the original coat is starting to appear on the surface and the rest of this layer is really thin. This action, sand, must be repeated at least until the surface are completely smooth, in my case was 4 times, and every time I used a thiner sand paper (last one was grade 800 and a light final sanding with 2000)

First sanding of B-737 yoke after first primer spray

Well, have you the control wheel completely sanded? Of course, waooo, I spent 4 days for this, ha ha ha...

Then, now is coming a really important step, paint it, why? well, this is the surface that we are going to obtain when we produce the mould itself, ok, then MUST BE perfect. After the layer of black (or green, or yellow, or the colour what you want to use...) we must be sure to apply a lacquer/varnish layer, that gave us a "mirror" finish, that should be perfect to make the negative mould and release easyly from the original yoke, so, this is as the final layer looks:

Final appearance of the B-737 yoke (mirror finishing)

Next step? mould it, but this is another history.

See you soon.

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