The framework for the cockpit is the bit that will hold everything together, mostly it wont be seen, but getting the dimensions right is fairly important so that everything fits together and has the correct shape overall.
Originally I was going to build the frame out of wood. The front panel of the cockpit was wood, and wood is relatively cheap as well as easy to work. I didn't have much experience with metal so hadn't considered it at all.
I used to work for a motion capture company in Brighton, and they used to build all kinds of crazy contraptions, some of which were built out of aluminium extrusion profile. It all bolts together without too much work so seemed fairly easy to work with. A few years later the company was clearing out some of the older structures and not being one who likes to see waste, I ended up inheriting a large amount out this aluminium.
Originally I was going to build the frame out of wood. The front panel of the cockpit was wood, and wood is relatively cheap as well as easy to work. I didn't have much experience with metal so hadn't considered it at all.
I used to work for a motion capture company in Brighton, and they used to build all kinds of crazy contraptions, some of which were built out of aluminium extrusion profile. It all bolts together without too much work so seemed fairly easy to work with. A few years later the company was clearing out some of the older structures and not being one who likes to see waste, I ended up inheriting a large amount out this aluminium.
Aluminium Profile
At about the same time I also got given a spare office chair from a friend, and I decided that It would do as at least a temporary seat for the simulator. So I bodged together a base out of the aluminium and managed to bolt the seat to it. As often is the way with these things, a rough bodge together seems to work quite well, and ends up remaining in the final construction.
This base was perfect for mounting the flight pedals and joystick that I discussed in my last post. The groves in the profile allow me to easily re-position the pedals depending on the height of the pilot.
Pedals which can be adjusted backwards and forwards
I made a few attempts to plan the rest of the cockpit dimensions, but realised fairly early on that it would be impossible to get the ergonomics of the controls as well as visibility correct on paper, so experimented with the positioning of the front console by building some rough stands. Its a good job that I did this, as it really is amazing how many things can be a problem that you don't foresee. Things such as the joystick blocking the visibility of the computer screens and getting enough visibility over the top of the control panel but without your legs bashing the bottom of it when using the rudder pedals. In the end I decided on the correct position having played a few flight sims using all the controls.
At this point I got very busy, as well as moving house, and so the whole simulator ended up dismantled in pieces buried in my junk room, under lots of other junk. There was so much work to be done on it that I seriously questioned if the project would continue.
Luckily a chance find restored my enthusiasm for the project again. About 3 years ago I found a post on the RPF forum where someone, had worked out exactly what seat had been used for the original X-Wing cockpits. Turns out it was a custom rally car bucket seat made in the 70s by an British company called Terry Hunter. No one had found an actual seat, but there was a photo of one as well as an old magazine advert for Terry Hunter seats.
Terry Hunter bucket seats were used in the original x-wing cockpits
The original RPF post where the discovery was made can be found here:
Although I wasn't too bothered about having the right seat (after all, you don't see it when you're sitting in the thing), I did think it would be pretty cool if I could get the right one. I checked ebay every month for over a year and didn't find anything apart from similar looking but very expensive Porche seats, so stopped checking regularly. Then, just before last Christmas, I decided to check on the off chance (the usual "classic bucket seats") and bang... first item on there.... Not only that, only £40 "buy it now". So I went up to Norfolk to check it out and was in fairly good condition apart from a few small marks. Perfect.... Turns out that it had been in a fairly famous car that had won the world rally at some point. The car had ended up in a museum for years and then recently some guy had bought it, with the intension of racing it again. Due to modern safety regulation, the whole of inside of the car needed tearing out and modern seats fitting (what!! you mean Luke Skywalker was flying in a seat that wasn't fireproof.... ).
My bucket seat from Norfolk
Having got my new seat, I couldn't wait to figure out how to mount it to my base so got everything out of storage.... Goodbye living room....
With minor modification, the seat bolted to the base surprisingly easily as everything uses M8 bolts.
That was easy
Having started building the base out of aluminium profile, It seemed easiest to build up the sides also with the same profile as it can all be adjusted easily. It also meant that the control panel and sides would be pretty strong, especially in the long term, if I ever decide to mount to a motion rig in the future. Having worked out the right positioning for the control panel, I was able to order the aluminium cut to size.
And here are some stills of my friend Wilx attempting to shoot some tie fighters in the simulator.
Now all I need to do is make the whole thing look good....
