ATR Engine Start Panel

As mentioned in this blog previously, the simulator that we have in our workshop is based on an ATR-72 and has become something of a test-bed for various components over the years without having had the time to properly complete it. The overhead panels shown there were the first iteration of ATR componentry that we used to sell.

Recently though, as the result of a specific customer request for some ATR overhead panels, we have embarked upon something of a re-design process utilising the same techniques that we've begun implementing across our entire range of panels. This includes fully backlighting them.

The first panel that we've just completed is the Engine Start Panel, as shown below:

The above photo (when compared with the photo below) gives some indication as to the amount of separation there is between neighbouring legends which are housed on the same annunciator; there is no light bleed whatsoever between the two halves.

Similarly below, in the korry switch that displays 'FAULT' there is no bleeding of the amber light into the well of the legend which reads 'ON' (and vice versa, had I thought to take a photo of it!)

Another challenge was the Prop Brake switch latch, which had to be loose enough to operate but tight enough not to fall open on its own accord (it's upside-down above one's head, of course). This problem was overcome by fitting a small customised spring onto one side of it.

Below is a photograph of what the panel looks like from the rear. You can see that it's supplied as one fully-populated unit, with all of the components pre-fitted to various mounting plates. For connecting up the korry switches, we've fitted 3-way connectors, which hopefully make things a bit more convenient and will lead to our customer spending more time flying and less time soldering!

Below is a very quick video (without any commentary) which demonstrates (hopefully) some sense of how solid the korry switches sound, and how 'positive' their action is ...

Custom Airbus Parts

We don't offer too many Airbus parts because there are already some fantastic products available elsewhere, although we do like helping to provide parts and panels that can't be easily found or which need to be built around specific dimensions and/or requirements.

The panels shown here were built for a simulator that incorporated various aspects of both an A350 and A380. We supplied a basic configuration file based around our own 64INS and 64OUT I/O Boards, which were interfaced to the Jeehall Airbus software.

Landing Gear Panel

Note: we actually had to re-make this front panel because it 

didn't survive the 19,000km journey to our customer!

TERR on ND Panel

Glareshield Panels

Blank Pedestal Panel

ISFD Bezel

Some custom 737 panels

As a continuation of the custom job previously documented here, the three panels shown below have all been designed to fit specifically dimensioned holes in an existing build, with our customer providing us good measurements and sketches of what he required. As a result of this, some artistic license has necessarily been applied here and there, although a good balance between authenticity and compromise has always been striven for - and hopefully achieved ...

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The Doors Panel

This view from the rear shows how the backing panel has been fitted onto the main panel itself, which means that the entire unit can be easily fitted into place without needing to make any allowances for any additional backing plate etc. and it's secured in place by a multitudinous array of screws to make sure that it's nice and solid.

This last photo shows the backlit panel from the side (before the rear 'light bleed' had been attended to, obviously) and gives some idea of how the embedded lighting allows it to now be kept well out of the way of the panel's 
associated hardware and/or backing panel.
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The TCAS Unit

For some idea of what's involved in the design process, specifically relating to the placement of text and components on any given panel, the following image 

was the basis for the above TCAS unit. 

As you can see, the shape of these two panels are very different - the original (above) is not very high, whereas the space required to fill in our customer's simulator (below) is - and so a lot of time was spent on trying to get the proportions right. 

Below is the end result ...

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The Wx Panel

An important part of designing any new panel also includes trying to replicate, where possible, knobs and buttons that also reflect those used on real aircraft parts of course. The above buttons and dual encoder knobs are an example of this.

This Weather Panel is actually going to be interfaced with our boards and so the buttons, which are backlit, have been fitted onto the rear of the panel by way of vero board. This might not look very pretty (hence no photograph from the rear!) but it's more than likely a once-off design and it'll work fine. It also means that once again there's no need for an additional backing plate - the components are already fitted.

Again, the screen capture shown below (along with the dimensions 

provided to us by our customer) provided the basis for our design,

which is here ...

Using our construction plans

Back in 2008/09 we helped one of our good friends build some of the parts for his Super King Air 200 simulator - a short video of which is here - and it is from these plans that our own King Air Construction Drawings originate.

Apart from the King Air C90 simulator that we built back in 2011 - which was based on these documents but with some minor alterations made to accommodate various requirements asked for by our customer - it's not very often that we actually get to use the plans ourselves.

Recently however, the opportunity to assemble both an Overhead module and a Fuel Panel module presented itself, so we took a few photos while we had the chance to do so. Hopefully seeing what these look like after they've been constructed will help any builders who are using these same plans better envisage what the end-result is likely to be.

Please bear in mind that some of the construction panels have only been temporarily screwed together for the sake of transporting the modules as entire units to our customer. Whatever could be safely glued and screwed has been, although these modules have been left unfinished as they'll be taken apart again when received and tidied up with sanding, counter-sinking of screws, painting etc.

Firstly, the King Air C90 Overhead module:

And now for the King Air Fuel module ... (we've previously supplied the Fuel Circuit Breaker Panel to our customer, so the panel you see here is simply a blank one that we've used to ensure the correct fit) ...

These modules have also been fitted with our latest backlit panels, which we'll discuss more in a future post.

Something else that we've done in relation to these plans is to design a glareshield unit that can be easily shipped. Shown in the photo below, it requires a bit of assembly work of course, but it's a good start and comes with the three separate sections and their connecting blocks, the engraved annunciators, PCBs with pre-fitted and correctly coloured LEDs, a connection PCB, and the necessary cables.