Hull construction

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Find your way into flight simulator cockpit construction

3.5 Hull construction

There are many variants on how to build the hull of your flight simulator cockpit. However, the more enclosed the design is, the more a flying experience will be obtained. Other things to consider are: easy breakdown for transport (not only the ability to break it down in to parts, but also the fact that the parts fit through the door / go down the stairs), accessibility (and also comfortability) and easy modification of (panel) parts (as you will develop advancing ambitions). If your final goal is a motion based cockpit, the structure should have enough strength of its own.

All kinds of materials can be used to get the effects needed. For instance specific metal structures can very well be copied using MDF, hard board, rounded nails for rivets and a layered (and sanded) multi colored paint job. Sometimes (related to your level of ambition) more advanced methods are needed to construct parts. At eMachineShop you can design your own parts and have them custom- made. If you need multiple copies you can use material like Alumilite Casting Resins.

It is also possible to buy real aircraft parts. Example sites (besides sites like eBay) for buying real aircraft parts are: BoneYard2U, Desert Air Spares, Sim Spares, OnceAloft, Scroggins Aviation, Warbird Parts and Konfederate Klassiks.

There are various options for cockpit construction, in the table below the basic principles and some examples are listed. For more examples see the links of builders and suppliers in section 2.

Real cockpit segment

The start for the flight simulator cockpit is the cockpit section of a real aircraft:

- WV838

- Alan Dyer's site

Hull-cockpit structures

Wanting to have also an aircraft impression on the outside some flight simulator cockpit builders build part of the hull structure:

- F16Sim

- SimHardware

Cockpit structures

The objective is to have a look-a-like effect on only the inside of the cockpit:

- Pascal Vonsey

- Nixon & Thomas

Portable cockpit structures

For those that can or will not claim permanent "footprint" for their flight simulator cockpit there is the option to develop a potable cockpit structure:

- xFlight/F16 (SimLight section)

Advanced desktop structures

There is not always enough room, ambition or time to create a complete cockpit structure. The alternative is and an advanced desktop structure.

- Francisco Garcia Garrido

- The V-Pit(cockpit in a closet)

- Monitor Canopy

Desktop structures

A desktop++ is shown on:

- Frank Bond

A very good introduction on how to construct a cockpit hull can be found at F16Sim in the sections "Cockpit Tub" and "Cockpit Hull" or at Flightdeck Project in the section “Construction diary”.

InstantCockpit (simulator hardware) comes half way between a kit and a self made flight simulator cockpit. It is created to replicate the seating position and control configuration of a general aviation aircraft and designed for use with the Yokes and Rudder Pedals from CH Products. Besides using it as-is, it can be the skeleton of your "real" flight simulator cockpit.

For the real Boeing 737 cockpit builders Project Magenta is offering a range of cockpit devices, varying from a complete hull to seats.

There are not many sites with details on building cockpit interiors (not being panels, throttles, etc.). For fighter cockpit builders there is a very nice introduction on how to build your own ACESII Ejection Seat.

The final touch on your home built flight simulator cockpit is the lettering and graphics that warn the crew, serve as a reminder, give directions or promote an aircraft brand. Using online services like SpeedGraphics and Custom Decals you can order custom made computer-cut vinyl graphics. Note that the use of computer-cut vinyl graphics is relatively wide spread, so the chances are high that there is a local supplier in your area. It is also possible to print decals yourself, see for example DecalPaper for the materials needed.