Author Archives: haoge

The cockpit has moved and i have a new CNC machine !!!

The cockpit has been moved from the basement into the cockpit room. You can see the current status on one of the pictures. At the moment i do a lot of work to fill out the empty places in the MIP. This needs a lot of time. When this work is finished i will take care about the throttle quadrant.

One interessting aspect maybe: I managed to get the FMC running on my android galaxy tab using the iview app. But it runs very unstable and the response is not satisfying. Maybe a new software update has fixed these problems – i did not check.

I managed to buy a new CNC router (Moederl) which is far better than my old diy router. Now i am able to do my pieces in much shorter time because i can run at higher feedrates. You can see the AFDS panel and also (yiep yiep) the first homebuilt pcb board for it. I also can mill aluminum now. This will be handy when it comes to a new gear lever.

Having a cnc router gives you the problem that you really need to spend a lot of time for planning the parts. My workflow is the following: The autocad dwg drawing is the source of all information -> panel export as dxf for Cut2d cam software -> in cut2d i plan the tool paths and create the nc code -> export to Mach3 Software which drives the router.

Recently i started to plan the panels in 3D with Audodesk inventor. This increases the ammount of planning time dramatically but i can be sure that the parts will fit together and i do not have problems in during assembly.

Overall, i am quite satisfied with my current cockpit but i see 3 major issues which cause headache for me. 1. The encoders used in the MCP have the known problem that the BU card does not read the signal fast enough so when i turn the encoders, the BU cards misses some detents. This problem is known but i didn´t get a good solution yet. I will make a new MCP and can solve this problem then using a LUA program or using alps encoders which simulated a turn of the know. 2. The MIP is not made out of PDF but out of some weaker material (MDF was oput in the shop when i bought the material so i choose other material calles pressspanplatte. Now i am not satisfied with the stability but i do not want to make everything new. 3. The room where the cockpits is installed is too small for 3 projectors and an enclosure : (((.

A last thing, when i ordered electronic equipment here in germany, i found out that reichelt has some good knobs which are not as expensive as the OC stuff… check this linkhttp://www.reichelt.de/Drehimpulsgeb…6ef5c099aa99ee

Cokcpit has moved into its new room. Visualization with 1x projector.

Cokcpit has moved into its new room. Visualization with 1x projector.

First PCB Board fresh out of the home production

First PCB Board fresh out of the home production

MCP Ver 1 finished

 Just some update on my project. The MIP is finished in terms of woodwork. Now i am ready to move the whole thing to my cockpit room for the wiring. For this i also ask for some suggestions how to approach the wiring. I have 2 BU0836X controllers from Leo Bodnar, OC Mastercard, OC USB Expansion card, OC Output card and 2 x Display card. I do not know how to approach the wiring in a good and organized way. I think i will place the 2 bodnar cards in the glareshiled behind the mcp as there are the most inputs at the moment which have to be connected. I also do not know how to make good connection which are connectable (and disconnectable) for fast connection of the components (should i go for 40 pin flatbed IDE cables ?).

Ok, as you can see on the pictures i most of the backlighting is done. I will install some 10 k potis to regulate the brightness of them.

The glareshield has been covered with black artificial leather over some 10mm softfoam matresses.

For the start i installed a 17 inch screen in the pedestal and will replace that with a touchscreen this year. The next steps will be wiring, installation of the missing components in the MIP, and getting the whole thing running with PROSIM737.

One major task will be to figure out how to mill the annunctiator holders and faceplates for them. I would like to see some gear indicators lighting up ; )

Detail of MCP. The backlighting is done with a stripe of white LEDS on a MDF sheet. This provides additional stability for the MCP.

Detail of MCP. The backlighting is done with a stripe of white LEDS on a MDF sheet. This provides additional stability for the MCP.

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First Test of backlighting is sucessful

First Test of backlighting is sucessful

First Version of MCP and some additional Informations

i think it is time to provide some updates for my project.

After i got my CNC machine running (with fixed chinese controller card TB6560) it is possible to do my own parts. So far the MIP structure is nearly finished and the first panel is backlighted. I use the SMD LED stripes for backlighting.

At the moment i work on the MCP. The front panel is finished and engraved (with 0.5 mm end mill) and backplate also ready. I do not use a 45 or 60 degree engraving mill because i have issues with the height of the panel. What i do is to set Z Axis to Zero for each new block of letter i want to engrave. The workbed is not 100% even so this is the solution which works good for me.

I did test with a self constructed engraving head but no big success.

Last week i received my first 500 € shipment from Open Cockpits with important components like master card, output card, switches, buttons and knobs. I did some molding tests to make my own knobs with silicon form and epoxy resin and you can see in the picture what comes out if you can´t wait till the mold is dried.

I try to get the MIP, MCP and EFIS Panels finished till i´ll move the whole structure into my cockpit room. For software i discovered the PROSIM 737 solution which seems perfect for my needs – not to mention that the package is free at the moment. Next steps will be all the wiring and of course many hours learning SIOC.

 

MCP Ver 1 front panel on the MDF router

MCP Ver 1 front panel on the MDF router

 

Engraved Letters and Backlighting

Engraved Letters and Backlighting

Gear LEver Panel and Backlighting

Gear LEver Panel and Backlighting

My first knobs fresh out of the mold

My first knobs fresh out of the mold

MIP Panel

The MIP (Main Instrument Panel) is probably the first part for any Homecockpit. It is the basis for the installation of important parts like the big displays or the landing gear lever. My MIP is made out of 10mm MDF material. The MIP consists of 3 parts which have been milled out on my old CNC machine. It would have been possible to make a single part panel (the CNC Worktable was big enough) but i prefer a modular approach.

 

The MIP attached to the basic structure

The MIP attached to the basic structure