COCKPIT / PANEL DESIGN:
Dad and I sit and chat about materials, dimensions, problems, solutions, etc. Meanwhile, mom brings us a couple of cups of coffee and the initial layout starts taking shape.



MUST BE MODULAR:
Possible issues with space and portability required the simulator design to include the facility for taking it apart and reassembly. Therefor a major concern while designing the panel/cockpit.

We use a poster of a Cessna 172 panel from Sporty’s Pilot Shop for reference.

The poster is pretty much exactly as the Cessna 172 panel from MS Flight Simulator, therefore an excellent reference for gauge and other instrument measurements.

Each gauge in a real Cessna is ~ 3” in diameter. On the poster it measures ~6.5cm, so I figured 6.5cm divided by 2.166 = 3". From that we started figuring throttle & mixture knob distances etc.

INCORPORATING THE CH YOKE:
Incorporating the yoke to the sim is a challenge because there are several options and additional challenges with each.

We decide cutting and extending the yoke would be the most realistic option because the shaft in a Cessna 172 extends Full back ~35cm


And goes Full forward ~17cm


Therefore we must extend the yoke shaft to extend ~26 cm from the panel with the yoke at neutral for a more realistic feel.


We take measurements of the Yoke control shaft (~1" diameter) and off to the Hardware store we went.




After much looking over several options and debating over whether to use a metal or plastic tube to extend the yoke shaft, we decide on a ~1” PVC pipe slightly larger than that the yoke shaft.
We chose 1" PVC mostly because it was the only pipe that would fit just right into a 1” electrical coupler that would take the place of a shaft support. 
We figure we can make this work with couplers and possibly epoxy.







POSTER BOARD PATTERN:
With the yoke shaft issue looking good, we buy some poster board and begin making the exact cut-outs carefully measuring monitor sizes and dimensions of all the components such as electrical coupler/yoke, throttle, etc.



CUTTING OUT THE PATTERN:
Now to wait for a day off during the week to take the poster board pattern and have it cut from a aluminum sheet.