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3.4 Panels

Just in case: the term "panel" is used for the boards in the cockpit that hold the gauges and switches. With respect to for instance cutting and engraving the formal "term" for a panel is "front plate".

3.4.1 Panel dimensions

When constructing a panel the first step is to define the layout. If you are in to modeling a real aircraft the issue is to find quality documentation about the panel layout (the shape of the panel and sub-panels and the type of gauges and switches needed including their locations). Since you will spend a considerable amount of time on the panel some additional effort in this area will pay off. The best start is to see if you can find an original manual. See the section “Cockpit specifications” for links.

In general manuals do give detailed information about the lay-out, however it is often hard to deduce the exact dimensions of the cockpit from these manuals. Additional sources are often needed, in many cases they are much harder to find. Examples are Varxec and Pietila. Browse also the builder sites in section 2. It is also possible to deduce sizes by using the size op a cockpit element you know the size of as a reference. On for instance eBay it is possible to get dimensions for single cockpit elements out of the product description, if needed you can even ask the seller a question about dimensions.

Instead of designing the panel by your self, it is also possible to buy ready made templates for panels. Simple to even very advanced panels can be obtained from suppliers like VFR-cockpit, Hispapanels, Flightdeck Solutions, Cockpit Sonic, Engravity and many others as you can find in the suppliers listing (section 2).

3.4.2 Cutting, engraving and lettering

The standard way of cutting and engraving a panel requires special equipment. One option is to look for a local supplier. An interesting alternative is a company that provides free front panel design software (Front Panel Designer) and facilitates the online ordering of the design you made. This is a very advanced service allowing you to make professional panels: FrontPanelExpress (for North America) and Schaeffer AG (for Europe). Some cockpit builders develop their own CNC machine (e.g. 737 Basement Simulator, Norbert Bosch) a good general starting point is CNC zone. You can also check for local suppliers that make panels based on CAD files made by you.

Instead of engraving a panel one can use adhesive materials for lettering. An example is the Computer Imprintable Label of 3M ScotchMark (DIN A 4 sheets for laser print applications in white matte polyester, transparent matte polyester and silver matte polyester). Also Dyna Laser provides some very attractive special purpose adhesive materials for use with inkjet or laser printer to produce front plates.

An other approach is to use printable overhead sheets or paper and put them behind a perspex sheet. An example can be found at ChrisB in the flight simulator project section. A similar approach is followed on the Boeing Cockpit Project.

When cutting the panel yourself, the making of the holes for gauges is a special issue. Be aware that there are special devices (hole saws) that you can mount on your drill to get larger holes with clean edges.

3.4.3 Back-lit panels

A special area of attention are back-lit panels. The principle is that the lettering lights-up when the panel lights are turned on. It is not really possible to copy a professional back-lit panel construction without special equipment and material, there are however very good alternative approaches. Examples can be found on the site F16Simulator, Biggles, Hans Krohn and on xFlight/F16 in the section "Simulator / Panels".

3.4.4 Fixing of panels

The panels have to be mounted on some sort of frame. Such a frame can be self made of wood on which you screw the panels. There are also very professional approaches like DZUS or Skybolt which can be obtained on the web or via local suppliers.