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Sep 05
It passed long time since my last update but this doesn’t mean that my project has been put on hold. I worked a lot during the whole summer to complete the knobs’ sets and rebuild the basic structure of my simulator. Here are a few updates about:

WEBSITE:

A timeline image gallery has been added. This gallery will host all the images updated by date, making a sort of movie of the cockpit build. You can access it here and bookmark.

KNOBS AND DETAILS:

I completed all the 23 knobs present in the glareshield and the Center MIP, but for the Master Caution and analog gauges ones. All of this had to be multiplied by 6 because I had many requests for them. The final result is astonishing even to myself and I hope the “fellow” builders will be happy as well with them. I also made some of the Switch guards present in the pressurization panel and made from scratch the caps for the DU keys and the RMU keypads with a new engraving and painting technic learned lately. Thanks to Ron Rollo of project45.us I also received a full set of smoke laser engraved lens that will fit my Korry replica switches.

IMG_1062 IMG_1075 IMG_1128

FURNITURE:

I rebuilt the whole MIP and pedestals part and I made a base for the simulator as well. The size of the base is 170×100cm and I decided after a real battle with myself to cut the MIP at 3/4 to allow it to fit easier in my small home. I just hope that the final look of the whole simulator will be nice anyway, and I’m betting on it, but I’ll envy a bit for sure all those that will have a full two seated simulator.

Earlier in August I got my MIP, glareshield and brackets cut and bent from aluminium sheets, and in the following days I made the base of my simulator out of wood and planned the more to come, like the center back column and pedestals based on Ron Rollo’s wonderful engineering ideas. As my MIP is slightly smaller and my shell will deviate from the full sized simulators, a different approach had to be taken from all the other learjet builders I saw images of. This deviation means more fun too! :-)

I planned the monitors’ stand to use just two monitors instead of the standard three. A 15.6″ wide for the pilot side and a 19″ wide for the center gauges and the right MFD. It has been a nice finding that I can save on a third monitor and then save the TH2GO needed for it or an additional videocard to drive the extra display. Even better that I had an Asus 19″ W193S 16:10 laying around so I won’t have to buy one.

IMG_1192 IMG_1202 IMG_1211 IMG_1210 IMG_1185

and as I had already made many of the center MIP panels here’s the MIP populating with them…

IMG_1165 IMG_1167 IMG_1184

Next step is the throttle quadrant pedestal and center pedestal. Those will sustain the whole MIP, glareshield and monitors’ weight so it is important they are very sturdy and steady. Many small details have been considered while planning it. Some had been needed to adapt the original TQ plate support, many others because I thought about where the interfacing hardware and eventually a computer should have been placed. A BU0836X is already in place and a Pokey55T will follow (I will talk more deeply about it later in a it’s own post. That is a wonderful all around interfacing board!)

IMG_1217 IMG_1226 IMG_1237 IMG_1241 IMG_1253IMG_1244 IMG_1246

Now I just miss to fix the glareshield over the MIP, but it will be only done after been painted.

To be continued…. :-)

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written by l45 captain

May 30
IMG_1043SS I’m making most of the knobs of the Center MIP and glareshield in this days. This include the RMU dual concentric knobs, all the DU knobs, the FGC ones and the EFIS controller’s ones. In total those are 23 pieces and I managed to make 6 full set that will be sold as well to some friends that are enjoying the very same project. Among other things I had to solve the problem to engrave some of them in series to obtain an overall same looking for all of them. I then managed to make my very first CNC automated Jig and wrote the gcode script to make the job I needed. Nice to say it has been a great success! I think that I will use such a way also for other things that need a replicated approach. Here are some images of a part of them and a video showing the Jig in action!

IMG_1032M IMG_1036S IMG_1052M

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written by l45 captain \\ tags: , , , ,

May 30
Trying to find a cheap and effective way to dim my panels, I made a lot of research around to web to find the right solution. Finally I found out some nice voltage regulators that can be used with a very basic circuit and make an excellent job. The LM338 is a 5A variable regulator that can manage any voltage among 3 and 36V and that with a simple trimmer/pot and a resistance drop down the voltage up to a defined value. It’s very cheap (2 Euros or less) and with as much as 10 euros of components you can make a board that can support up to 250 leds or 50 grain of wheat bulbs. Downside is that the much power it has to dissipate the much it will get hot, so an heatsink is required when you use it with 9V or up supply.

IMG_1003MVRB_BoardM

The circuit is basic. The LM338 in the TO220 package just has 3 pins, Input, Output and regulation. the output pin is connected to a 120ohm resistor as feedback and tied together to the output pin of the pot. The regulation pin is connected to the pot to variate the voltage down. There are many calculators around the web to choice the right pot max resistance in relation to the needed application.

A smaller version with 1.5A is also available, the LM317. But because of the very cheap price I would anyway go for the LM338.

You can have further information about here.

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written by l45 captain \\ tags: , , , , ,

Apr 29
color_comp

I found out some interesting details about the learjet 45 that might interest some. The very first information is about the cockpit panels color that was really hard to identify. Even with the original TQ plate I got I wasn’t able to had a correct matched paint to work with. Finally I run across a confidential document that shows clearly that the color used is the FS-36118. This is a very common color also used in the model builders area and called Gunship Gray. Tamiya (TS-48) and Humbrol (HU164) among others main paint suppliers have it in their catalog. Here’s a comparison between the worldwide used RAL 7011, the FS-36118 and the commercial paints. As you can see the difference appears small though the Humbrol one is a bit clearer and the Lifecolor with a more decise blue tint.

The second information is a document I found about the DZUS fasteners used in the cockpit. Buying those original might cost as much as most of the self made cockpit itself and even some well known manufacturers that makes mockups sell those very high priced. The CNC came handy by having the right measures and I made a whole set of three dozens of those little pieces.

IMG_0907B dzus

Third and last a technical information about the screws used to fix things to the MIP. There are two main types used in the learjet. DIN-84 are the same shape and cut as the ones used in the DZUS. DIN-7985 instead are the philips type used in the lower MIP panels and on the main MIP. Those screws are very easy to find and cheap. Alleluia!

spec_din84spec_din7985
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written by l45 captain \\ tags: , , , ,

Mar 26
IMG_0754M After long trial and two different versions of it, I completely finished my RMU. The first time I just tried to make it almost similar to the real Honeywell gauge, just concentrating my efforts in making it clean and functional. Anyway after I had completed it I felt that it wasn’t really what I expected to realize, even if it was nice looking and, as you could have seen in the video in a my previous post about the center MIP, well realized. So I started from scratch and with the data obtained in the first run I focused on the many details present in it, overlapping real images to my drawings to find the one and very harmonic feeling it has. Aircraft parts are not only functional but nice looking too… Now I have to say that I’m proud of it. It’s really a small piece of italian art!

IMG_0762M

Continue reading »

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written by l45 captain \\ tags: , , , , , ,

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