-Ice

Thanks for that Pogo. Unfortunately, I am using a car seat and not an ACES II replica, which means I do not have the center-gap on the seat, thus the fancy-schmancy extender.

I've thought of that yes. I'm thinking of using a 90-degree one for the bend just before the stick handle as that's the trickiest one; if I can do that, the rest of the bends are easy-peasy.

I've not played with it on the PC yet, but yes, you'd have to help the stick back to center. On 40% to full deflection, the weight of the stick can keep it in place. I'll have to see how this works in-game. However, I've played most of my DCS A10 games with a stick extender, so can't imagine playing without it now. The downside of using a car seat instead of an ACES II replica is having to fashion a fancy-schmancy extender tube rather than using the replica extension which only has 2 bends in it.

Thanks for the advice regarding tube bending. The sand does help the tube keep shape, but only up to a degree. My shape still ended up with a few kinks, but looks loads better than the last one. Here are some pics of my test bends. Here is my bending "template," I'm thinking bigger nails and smaller spacing between nails will help reduce the kinks in the bent tube. Finally put in the 6mm MDF panels on the side consoles. I've not put any rails on the side consoles, instead screwing the MDF to the rib assemblies. This will have to do until I figure out how to do the actual instrument panels, and even then I'll just probably remove the MDF as an instrument panel takes its place. Also cut out the front instrument panel and fit my TM MFCDs. Crash, thanks for the kind words. Had to "rush" this project since the longer it'll take, the lazier I'll be. That and I had loads of free time last week being my holiday from work. I would've considered a metal pipe but could not find one of 25mm diameter, which is how wide my joystick extender holders are. Plus I prefer bending the tubes myself. As you can see, the pit is pretty much 90% complete. The instrument panels and switches will come as I get the budget for it, and will definitely be a WIP for months to come. Probably try to figure out how to fit a monitor on the front panel for instruments, but no rush there as well. On the immediate to-do list is a CDU panel and AHCP, but will have to wait until my funding is approved. :thumbup: Now just need to give this a proper wipe to get rid of all the wood dust, and assemble it in the computer room!

Ragtop, do you have measurements for the top-outer sections of the side consoles? I've tried test-fitting my 6mm MDF and could not figure out the fit for that last secton, it would always bring up a gap at the center.

Here's my latest progress report! Built some braces for the front panel, cut to the right height for my monitor. With this, my "eye level" is about the top 1/3 of the monitor, which is just about right for me. Again, I am following my "I will not screw MDF-to-MDF" rule. I've sorted out a mount for my TM Warthog joystick as well. I prefer this method because if I needed to remove my stick for any reason, all I have to do is unscrew the four screws on the top and sorted! I'm screwing MDF-to-MDF on this one though, but the plan later is to have a bolt running clear through, just like in my seat assembly. Found some 25mm "cable tube" from B&Q, hoping to build a stick extender. Also, here is a pic of my new, higher seat! I must admit at this point that stick extender is more like a "proof of concept." The way I made it to bend was to heat up the tube for a moment and then bend it by hand, then cool quickly through the cold tap water to "hold" the bend. However, the bends are a bit wonky and bending too suddenly means the tube will fold unto itself, so passing a USB cable through it will be impossible... does anyone know a better way of bending a plastic tube?

Thanks Dimebug! Wouldn't be possible without your plans! 98abaile, my front panel is exactly as in Dimebug's plans... well, not exactly coz I haven't cut out the angles yet, but height-wise and width-wise, it is exact. The reason I'd rather play with the seat height is because it is easier to do so and it's just like a pilot adjusting the seat height in the aircraft. To do this on the consoles means I'll have to recalculate and screw/attach/remove the necessary risers.

Thanks for the complements guys! Aseembling the entire thing now, figuring out how to attach each part to the rest. And wondering how to do the Dzus rails on the panels. Awww, do I have to?

Very nice!

avlolga, I think the space cut out on each rib is enough for the wires when I eventually make the panels. If neccesary, I'll just cut some more material out of the gaps, but I think it is enough for now.

I do have a few bits of MDF about, from spare cuts and such and the "overrun" from my 2 2440x1220 sheets. Unfortunately, I bet shipping to Rio will be a pain. I'm sure there's some MDF in your area, though it might have a different name. Construction shops and DIY stores would have them. Here's a few more pics of my progress. I'm calling it a night, since I have to work tomorrow. Two weeks and then another week's holiday. Yay! This is the front panel/console starting to take shape. At first I was worried my Saitek rudders might not fit but after a test-fit, there was nothing to worry about. Here's the underside for the console floor. I'm really paranoid regarding structural integrity so there is no way I'm screwing MDF-to-MDF. The solution? MDF-to-timber-to-MDF! Test-fitting the Saitek pedals to be sure... And a few more material in place... Here is a test-fit of all 3 consoles together. I must say I am a bit worried about the whole assembly being too low to the floor, but then again that just makes getting in/out easier. Here's the work done on the seat. At first I planned to have two beams running left-to-right to support the weight, but for some reason I've measured the distance erroneously so I had to put one beam per side. After that test-fit, I put in the MDF flooring and attach the side supports. Basically, the flooring is there to keep everything neat once the seat is turned upright. The beams are there to provide additional structural support both for the seat and for the supports for the entire assembly. Here is the seat ready to use! And test-fitting the entire setup... After a few minutes sitting on the chair, I think the seat is too low with regards to flooring and the front instrument panel so I think I'll be raising it by a few more inches tomorrow. This is easily done by removing the side-supports (the ones screwed on the beams) and replacing it with different heights. So technically I can adjust the height until perfect! Also, my seat somewhat widens at the top so with the way it is now, the right console has to be off to the right by about 20-23mm to make room for the seat --- not really enough of a bother, which will probably resolve once I raise the seat up a bit more. I also need to find a way to secure all 4 sections of the cockpit together. The left and right console can essentially clamp onto the front console, the clamps being placed at the incline risers going through the front console floor supports. Attaching the seat assembly to this whole setup will be a bit of a challenge. I'm also thinking of a way for the right console to be put out of the way, either by swinging to the side or something, for ease of getting in and out and for the additional "cool factor." I've not mounted the front instrument panel just yet, still working getting it to shape. A front panel of 18mm MDF sure is hefty! I'm thinking of having it replaced with maybe a 9mm one in the future. Since I'm also mounting my LCD monitor on this setup, I need to work out something that will act as it's platform behind the front panel... no sense working that out until I've got the front panel in place and have played around with the seat height. Looking back, I wish I hadn't put the top-angle on the montant and flanc externe pieces as I'll technically have to un-do this angle to mount my monitor properly. I guess the original idea for this build was to have a projector shining through the back to display instruments and such and thus needed an angled pane but for my purposes, I've just done extra-complicated cutting that I didn't really need. Oh well, lessons learned. The great thing about this being a modular build is that I can always scrap the front console later on if I want to build a new one, or maybe just replace the montant and flanc externe pieces with properly cut ones.

Priceless, thank you sir!

Got up at 9:30am this morning, had breakfast, then acquired permission to resume my build. :) Best to clear everything with the boss before you do anything, hehe... Finally figured out how to work the circular saw in the wee hours this morning, so I put that new skill to good use. Here is the montant piece before and after cutting: The circular saw does generate a lot of dust, more than my trusty jigsaw. Luckily I bought a mask yesterday. This, gentlemen, is wood POWDER. Was not long before I had most of the material for the front console all cut nice and even. Photo uploaded to photobucket, shows up oriented properly there, I wonder why it's still on portrait mode here. Any ideas? Now working with putting things together. Already told the wife she should start thinking about how she wants her shoe rack and step stool built. :D

Will post pics in a few... and no, no sexual acts was done in the building of this pit, and no family jewels have been lost or otherwise harmed in the making of this project. :D

No worries there, I was just surprised that there weren't any dimensions/measurements for these, considering how anal-retentively accurate the other PDFs were. :D I'm not necessarily making the front panel instruments yet, but was hoping for the info so that I can structure my LCD supports properly. Oh well, I guess I can revise them later as I build the front panel... or maybe even build a different panel entirely and just swap it 'round once that's done.

Bump! Figured out the angles on the bits I needed, starting work on the front panel itself. However, I find this a bit... bare with regards to measurements and angles. Also looking for measurements of the panels (AHCP, engine instruments, etc.) on the front panel, how big are they? Spacing?

I think I just made the circular saw my beyatch! I got one for B&Q earlier today and tried playing with it, seeing how I can make accurate cuts with it. For some reason, I couldn't seem to make anything decent, whether going by the guide, the saw cut, or the laser. I gave up after 45 minutes and went back to my jigsaw and built the right console, thinking I was going to return this saw sometime soon. With the right console done and still wide awake, I decided to at least measure out my center console panels for cutting tomorrow. Oh boy! Lots lof fine, straight, long lines to cut with a jigsaw! Tried playing with the circular saw again (yes, at 1:30am!), and finally figured out the distance from the edge of the guide to where the teeth cut! Yay! After a few more trial cuts, I was ready! I clamped the two pieces of boards that was going to be my flanc externe, aligned my guide, positioned my material squarely on the workbench, and started cutting. Whoa! This thing sure is noisy, I hope nobody calls the police at 2am and complain of somebody using a power tool!! And it spat out wood dust everywhere! However, taking my setup apart, I was rewarded with a very dusty room and a very clean, very precise cut on not one, but TWO boards! Whoo hoo!! Looks like the center console will be done by tomorrow evening after all! Ragtop, I will be doing the center console as per Dimebug's plans with a few exceptions: 1) I will not be putting in a cloison avant, 2) the front panel will be clean/plain, and 3) the top will be a bit lower, so that my screen is about eye level and the lower bevel of the screen will be about flush with the edge of the front panel. There will be supports behind the front panel to support my monitor, but aside from that, it will be close to Dimebug's plans. I hope it will be a nice day tomorrow, I need to do my cicular saw cuts outside, the amount of dust this generates is just insane!

Hmmm.... always thought that the holes were for "saving weight," I don't think we'll be running cables and cables through this. Lol! However, will need to sort out cable management once I cross that bridge. Starting on the center console now, while everyone is asleep, sneaking in some work during "quiet time."

Isn't the U-shapes on the top enough space for the wiring?

Thanks guys! Sorry I was not able to post yesterday, finished building the left console and stuck the inclined risers with wood glue. Decided to close my eyes for 30 minutes while waiting for the glue to set, next thing I know it's 4am! Anyway, here's some progress pics! My temporary work area. I've cut my panels in the shed behind the house, but nothing beats a nice warm room when you're working, eh? Test-fitting my TM Warthog throttle... My cuts aren't too perfect so there's a bit of a gap here and there, but no worries. You'll also notice that my throttle mounts look different... that's because I took the tops off over the throttle screw holes. I like the idea of everything being secure in place so I'm planning to screw the throttle into the console assembly. A few bits of would to secure the throttle to... A trip to B&Q again to get some 6mm MDF for the panels... I think I got a bit carried away... or got my measurements wrong. Oh well, nothing wrong with extra material lying about! What amazes me is that it costs £7+ for a 1220x607 sheet, but only £10 for a 2440x1220. So guess which size I went and bought? And here is my work done for today... clamping and curing the right console incline risers. You'll notice that most of my rib assemblies do not have the hole cut into them... still need to find a trick to quickly cut into annoying little box-shapes. I know the trick with the drill, but not too happy with it. Still, I'm thinking, the heavier it is, the sturdier it will be, so not too fussed about it. HHF, you're warning came too late, mate. Already got an order for a shoe rack and a step stool from the big boss. You're right though, nothing beats the eyeball, though I've noticed that even if my cut is straight through the pencil line, sometimes the cut itself isn't square. Need to learn to relax and drive the jigsaw and not to pull it. Ragtop, I sure hope I finish this project in less than 3 weeks! I'm just aiming for a proper setup, obviously all the panels and lighting and switches will be a WIP, but getting the proper "cockpit form" is my goal before I start work again on Monday. 98abaile, the current plan for mounting the seats is to mount them onto two 47x47mm blocks of wood which is going to be raises above the ground by a certain amount. This height is going to be decided by how the seat fits into the whole setup... when I've decided, I will attach the seat through a "floor" of MDF and through the block of wood I mentioned earlier, and will be secured with bolts. Hope that helps. I'll post a pic once I get to that stage.

Very nice work there, Ragtop. What did you use for the panelling again? Was it 6mm MDF? Been to B&Q today, saw them selling a 3mm hardwood sheet, wonder if that'll work...

Finally had the time and resources to get materials to build my cockpit, so eased off into B&Q earlier today and got me some building tools and some material. As I've just moved to the UK 18 months ago, I'm starting from scratch, so I had to get me a jigsaw, a bench, and some other bits-and-bobs. I've even had to go to WH Smith to get a protractor! :music_whistling: I've decided to get as much material as I can... don't have a car at the moment so trips into B&Q can't really be spur of the moment type trips. Two 2440x1220x18mm boards cut up into itty-bitty pieces, more than enough for the two consoles, the front dash, and my seat mount. I've managed to luck on a couple of sporty car seats for a reasonable price, which kinda kick-started this whole project. Quite a bit of scrap material to practice on! Here's the material for the seat base and for both side consoles. Thanks to Ragtop for sharing his experience with me; everything for the consoles fit in one 1220x607x18 sheet of MDF. The material for the seat base was taken from the other MDF sheets. Most of the 3 other MDF sheets were used to create material for the front dash. Thinking back now, some parts could probably have been made out of 12mm or even thinner MDF... that front panel alone is very heavy! I've bought a few lengths of kiln-dried wood as well for structural support the consoles. I've also been warned not to do MDF-to-MDF joining so each butt joint won't actually be joined to each other but will be screwed onto a piece of wood. This is the first time I'm using a jigsaw so still getting used to it. The laser has not helped at all with doing straight cuts, and the side guide gave me a cut that was +/-1mm from what I wanted. Oh well, not bad for a first-time user, but any tips appreciated! I got a 750W, pendulum, variable speed jigsaw, I've not yet appreciated the difference between a slow blade vs a fast one, but boy, does this tool make a lot of fine dust! I thought at first I could work in this room for the rest of the build but it's probably going to be a pain; better to do the cutting outside in the shed then just work in the room during assembly. Many thanks to Dimebag for his templates, he's saved me from having to come up with all the measurements! I just hope my seat will fit later on! At the moment, my plan is to simply build the consoles, mount my Warthog, figure out the correct height for the seat and the monitor, and start playing. The consoles will be skeletal for now, until I can get some thin MDF to cover it. I will then start working on building the panels I use a lot like the AHCP and countermeasures panel. I'm hoping for a CDU panel later on, but with each button costing £1 each, that's going to be a pretty expensive CDU! This pit will be a WIP for a long time to come!

Dammit, this is quickly getting out of "wife-friendly" territory. I see work bench going for £20, does that look good? And clamps for £5...

Sorry about that, I did know about Dimebag's PDFs but couldn't make sense of them until now. While this "solves" the console and front panel issue, I still don't know how far apart the consoles have to be with each other. However, I've got more than enough to work with and like Rok, I'm going for comfort first then realism, but I like to know what the "real thing" is before I tweak to my liking.

I just realized one thing -- I don't have a workbench to do all my cutting. I'm going to get the store to cut the general shape for me, but that still leaves a lot of angles to cut out for myself. Easy enough to get a jigsaw (any blade recommendations?), but no actual workbench! Seems like I'll need two 2440x607 sheets for the front panel... three sheets in total, with a bit of extra for my seat base. Any other tools required for this project? Protractor, ruler, jigsaw, drill...