|Flight Simulator Boeing 737NG|
Boeing 737NG pictures>> Last update: July 2020
2. Gen. Simulator
For a long period I have wished my pilot seat adjustable in high and back rest angle. I have all ready made some drawings of the rebuild but realised it will be a difficult and time consuming job. Instead I began to look for a used IPECO seat on the Web.
I found one at swiss-sim in Arizona. The seat is a 29 year old IPECO pilot seat removed from a Boeing 737-400. Two weeks later I could pick it up at Billund Airport.
Sheep skin on the back rest was missing so I have ordered new sheep skin covers for backrest and seat. Mechanical I have only repaired a broken spring and made some missing nylon bushings. Otherwise all functions was working well and luckily the seat fits my J-rails from Simujabs perfect. There was no Head Rest with the seat and the Head Rest from my old seat did not fit so I have made a new one.
My old home build pilot seat is now for sale.
In this year I have also
extended my cockpit floor for better room to the "jump seat" .
1.Gen. Simulator at August 2007
I have used MS Flight simulator since 1995. My Boeing 737 Simulator Project was started up 2006 with cockpit seat, controls and throttle levers. The controls were connected to my joystick by cables. All was placed on a base facing my old desktop computer.
In this simple and inexpensive simulator I have had many good flights until I changed over to a for me more complex simulator technique in 2009.
more pictures>> (Text only in Danish)
Pilot seat was the very first part of my Flight Simulator Project (2006)
Dec 2012: Seat rebuilt to NG-style with headrest. On the same time the back rest has become adjustable.
June 2018: The old straight rails replaced by new J-rails from Simujabs and home made bogies and seat lock.
July 2020: News My home build Pilot Seat is now replaced by an old IPECO pilot seat removed from a Boeing 737-400
Rebuild in the winter 2008-09 with potentiometers instead of my old joystick by cable solution.
Dec 2011: Nose wheel steering is working. It is now possible to handle the plane on ground at low speed (below 45 knots IAS) by the tiller in left side. Above 45 knots only the pedals is working.
Build and installed March 2019.
On the AFT OH-Panel there are two Stall Warning Test bottoms. May be you can find a sound file to simulate the shaker, but I decided to design and build a real Stick shaker. When you press test bottom the shaker start after some seconds and run for a short time. In flight it depend on Aircraft configuration weight etc. when the Stick shaker start up but you can hear it loud and clear and feel the vibration in the Yoke too.
Build winter 2007-08. Electric wired and connected with computer 2009
Mar. 2014: After running ProSim the trim
wheels also are working when flying with autopilot engaged. My noisy trim
motor (Bosh accu drill machine) is therefore replaced by a small silent gear
Engine Start- and light panel build in winter 2008-09. Feature: Electric Engine Starter switch cut out
Rest of the FWD OH-Panel inclusive instruments is built winter 2010-11.
2014: OH-Panel now alive with ProSim and OC interface cards
2015: Engine Start Switch now with push before turn function. Also new YAW-Damper and Wing Anti Ice switch with electromagnetic hold.
2019: AFT OH-Panel add
Main Instrument Panel
Landing Gear lever unit build in winter 2007-08.
Has been replaced by a new unit Jan 2015 (see below)
May 2012: Also
for the MIP I have used acrylic. Base panel in 3mm sheet cut in one piece.
The different panel sections are also in 3mm and at last the 3mm light panels (Opencockpits
and some home made). Frames for monitors are made of MDF. An alu-profile
in top and a profile of wood in bottom give the panel stiffness.
Landing Gear Handle
New handle with on ground lock and working lock override finished Jan 2015.
The unrealistic function of my old handle from
2008 has worried me for a long time so Dec 2014 construction of a new
more realistic version was started up.
Pedestal build in winter 2010-11.
Dec. 2013: Pedestal finished with VHF1-,NAV1-,ADF1- and ATC Modules from Opencockpits. Dummy radios and the other panels for the pedestal are also from OC.
April 2014: Cargo Fire and Trim panel now working with ProSim.
Nov. 2014: New working NAV2 module replace my NAV2 dummy
Mar. 2015: I purchased the FMC/CDU from Opencockpits. Some modifications of the CDU and the bay was necessary before the unit could fit in my old bay.
Frame for lower DU is ready.
Jan.2016: I purchased the CDU panel from Opencockpits for the 1. officers dummy CDU.
Mar.2016: An old 14" notebook monitor with a spec. LCD-controller board is now working as lower DU.
Engine Fire Panel
Engine Fire Panel build in winter 2010-11.
April 2014: Panel connected and it is now working fine with ProSim.
June 2018: Cockpit extended with new build AFT Side Wall Liners and Window. FWD Side Wall and Window are rebuild at same time.
Glare Shield and Glare Wing rebuild to fit the new windshield position.
June 2018: Old eye-brows rebuild. New build ceiling and FWD Drip Tray
Cockpit Lamp for the left Side Wall and another Lamp for the Eyebrow Window build in winter 2010-11
Feb. 2011. At last I got my projector. I have now the Cockpit View on a 120x160cm screen in front of my Cockpit. What a different it has really improved the simulator. Some times my brain get cheated and I feel the cockpit is moving.
Mar. 2014: My old DVI - VGA cable between PC and projector is now replaced by a 5 meter DVI - HDMI cable (price10€ ). This has improved the outside view quality a lot.
Switches and knobs
June 2011: Many different switches and knobs are used in the simulator. Most of the switches are miniature (ø7mm) model modified with a self made turned handle in aluminium. The handle is glued to the switch and in fact the max. diameter is 5,6mm it is possible to mount and dismount the switch afterwards. The small and big white rubber caps I have got from Engravity. The B737 standard knob is also from Engravity but special knobs I have made of wood.
See also my EFIS and MCP module (Opencockpits) with modified knobs and switch.
Dec. 2013: Self made special knobs for the Cargo fire panel, WX radar, Audio panels, Rudder trim and Cab. door lock panel are finished. I have also made new handles for the the four Landing light switches. more pictures>>
June 2011: 7 different gauges for the FWD-OH panel and a Flap Indicator are finished. Build in 3mm acryl and housing of ø 50mm PVC tube. The needle is moved by a little RC servomotor directly or by by gear wheels if the movement has to be greater than 180 degrees or if a dual needle instrument. Gauge face is printed and the whole is covered by a 2 mm acryl glass.
May 2013: Yaw Damper and Brake Pressure gauge
for the MIP are finished.
Various cockpit elements
Oxygen mask panel Oct. 2012
Fresh air panel Oct. 2012
Check board Oct. 2012
Left side wiper Oct. 2012
Magnetic standby compass is finished and now working Dec. 2013
iPAD tray Feb. 2014
New MAP-CHART light panel Feb. 2016
Rebuild Rudder Pedal adjustment and new liners Aug. 2018
Document pockets for left sidewall and throttle pedestal May 2019
ATC-sound to headset and/ or overhead speaker November 2020 News
Electronics- PC- software
I use I/O Cards from Opencockpits. USB Expansions Card, Master Card, USB Axis Card, USB Servos Card, USB Stepper Card, Relays Card and Connector Cards for easy in-/output connections.
Programming software SIOC.
2014: System logic and Display Units now by ProSim 737 Suite
2014: New PC and software
2017: The new DC Motor card for the Throttle has caused some changes in the interface card layout.
2019: AFT OH-Panel and Stick shaker has caused some changes in the interface card layout.
Parts from my simulator project not longer in use.
- Pilot Seat
- Sheep skin cover used from IPECO seat
-Sheep skin cover Backrest for IPECO seat.
- LE DEVICE + IRS Panel from OC