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DIY Flight Sim Projects

Pilots and those who long to fly must train in simulators before they're allowed to take a plane into the air. Private pilot's licenses can be earned with as little as 2.5 hours of simulator time, while commercial pilots must spend as many as 50 of their 142 hours of training time in a simulator. With a collection of flight control hardware, a computer and video screen, PVC pipe and a bit of imagination, amateur pilots can build a flight simulator at home that helps them prepare for their licensing tests.

Things You'll Need

  • Computer HID (human input device) flight yoke
  • HID throttle controls
  • HID rudder pedals
  • Computer
  • Flight simulator software
  • Video monitor, 21- to 27-inch
  • PVC pipe, one inch
  • Assorted PVC fittings including elbows, ̶0;T̶1; caps
  • 1-by-10 #2 pine board
  • PVC glue
  • Acetone
  • Clean rags
  • Rubber gloves
  • Hack saw, miter saw or PVC tubing cutter
  • Measuring tape and pencil
  • Drawing paper
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Instructions

    • 1

      Research the dimensions of your favorite airplane cockpit. Flight sim software packages include many airplane types, and each pilot has his favorite plane. Get pictures of the cockpit layout and scale drawings, when possible.

    • 2

      Make a rough sketch of the cockpit, including the location of the three major controls: the flight yoke or joystick, throttle controls and rudder pedals. Using a tape measure, identify the positions for the controls. You can use a desk as a starting point, or estimate the locations of the flight controls by sitting in a chair and placing stacked books around you to closely approximate locations for the controls.

    • 3

      Measure the distances between these control devices, such as their height from the ground, relative position from one another and their location in relationship to you. For example, record how far from your side the throttle controls are located and how far in front of you the rudder pedals and flight yoke are positioned. Transfer these dimensions to your drawing.

    • 4

      Using 1-inch PVC, construct a tubular frame based on your drawing that will support the three flight controls in their relative locations. PVC is simple to work with, and 1-inch PVC is fairly rigid, lending its strength to the flight sim tubular frame. Using your drawing, fabricate a tubular frame that holds the flight controls.

    • 5

      Assemble the frame without gluing the pieces together. Slide the pieces of pipe into the fittings and test your PVC ̶0;cockpit.̶1; Add support tubing to create a sturdy, free-standing frame.

    • 6

      Cut a piece of 1-by-10 pine board and screw it to the frame in the proper location if you need a flat surface to mount the control peripherals. Both the pine boards and the PVC pipes cut and drill easily. If you make a mistake, or in the worse case have to start over, each attempt will help you create a more realistic and stable wraparound cockpit for your controls.

    • 7

      When you're satisfied with your creation, use the applicator in the can of PVC cement to glue the pieces of PVC pipe together with the fittings and couplings. Paint a coat of the cement around the outside edge of the pipes and wet the inner surface of each fitting as well. Slide the pieces together and hold them for 10 to 15 seconds while the glue tacks up. PVC cement sets quickly, so you can use the cockpit frame as soon as you finish assembling it.

    • 8

      Place a small table behind the tubular cockpit that's at eye level when you're seated. Place your computer monitor on this table, then connect the computer to the peripherals. Mount the peripheral flight controls into the tubular frame. If you plan to use the flight simulator occasionally, remove the peripherals from the frame and try mounting them into place with heavy-duty, self-stick Velcro. While in use, the peripherals will stay firmly in place and the Velcro will allow you to remove them easily.


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