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Birth of a Wharthog...


geneb

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you. are. killing. me. Gene

skunk160 | Win10 PRO 64bit | i7-4770K 3.50 GHz | 32GB DDR3/1866MHz | GIGABYTE GeForce GTX 1080 x2 | Oculus Rift S | Virpil MongoosT-50CM2 | Virpil F-14B grip | Virpil 200m Curved Extension | PointCTRL | Delta Sim TM Slew | Sim Bandit AHCP | MFG Crosswind Pedals | //FOX2 Switch Boxes | RECARO SPG Seat | AuraSound AST-2B-4 Pro Bass Transducer x2

//FOXTWO Multi-Role Combat Pit Build http://forums.eagle.ru/showthread.php?t=134745

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  • 2 weeks later...

Ok, here's the last installment...

 

First, let's get the seat pan knocked out. It's a really simple assembly.

Sorry for the blurry pic. Cell phones can only do so much. :)

 

seat-pan.jpg

 

I traced a center line about 8mm in from the edge and drilled & counter sunk four pilot holes for #8, 1-1/2" screws. I then applied glue to the seat side and attached it.

seat-pan-bottom.jpg

Do the other side and you're done with the seat!

 

Now, grab one of the large side parts and the seat support "greebles". Coat that sucker with glue and tack it down:

 

greeblie-gluing.jpg

 

Flip the side over and install the seat bar support:

seat-bar-support.jpg

 

Install the outer greeblie and the support on the other tub side - MAKE SURE THAT YOU'VE GOT THE SIDE MIRRORED! If you don't, you'll have two lefts or two rights and you'll be pretty cross when it comes time to assemble the cockpit tub. :)

 

Each tub side has three greebles attached to the outside surface. The next series of photos show how they're installed. The left tub side is shown in the photos.

 

Aft end.

side-greeblies-1.jpg

 

Center greeble.

side-greeblies-2.jpg

You can get the same glue bottle I'm using there from Rockler online. It's VERY nice for applying even coats of glue to a large surface area.

 

Center greeble installed.

side-greeblies-3.jpg

 

Fwd greeble

side-greeblies-4.jpg

 

Repeat that process for the right side.

 

The stick base...

 

stick-base-1.jpg

stick-base-2.jpg

 

The stick base goes together pretty fast. The original CAD drawings called out for a slot in the part shown installed below.

stick-base-3.jpg

 

There's supposed to be a triangular shaped support part that fits in that space, but because of that slot, there was no practical way to install it. If you're making your own Wharthog, delete that slot.

 

Because the support part wasn't usable, I used four #6 screws and glue to solidly mount the little plate that supports the stick base plate. Note that you'll need to drill out the four holes to 5mm if you haven't already. You'll need 4 M4x16 screws to attach the Warthog stick to the base plate.

 

Now start the process of getting things assembled. I did a test assembly of the aft section on my work table because it was easier to photograph.

 

assy-1.jpg

 

assy-2.jpg

 

assy-3.jpg

 

assy-4.jpg

 

The vertical side shown in the photo above doesn't like to rest in place. I strongly suggest you look into the use of threaded inserts if you're not going to permanently assemble the left & right tub sides.

 

assy-5.jpg

 

assy-6.jpg

I used a 3/4" Maple dowel for the seat back support. I _think_ it's about 21"

 

assy-7.jpg

That finishes the cockpit tub assembly! Now let's move on to the forward section.... (in the next message. Why? Because the forum is mis-configured and only allows 20 images per post. *facepalm*)

g.

Proud owner of 80-0007.

http://www.f15sim.com - The only one of her kind.

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...continued!

 

 

fwd-assy-1.jpg

 

fwd-assy-2.jpg

 

fwd-assy-3.jpg

 

Next, you'll want to set up the left & right panel "leaves" as shown in order to clamp the instrument panel to them.

 

panel-alignment-1.jpg

 

panel-alignment-2.jpg

 

Once you've got the panel aligned & clamped in place, move it to your work bench so you can glue & pin the panel to the leaves.

 

panel-alignment-3.jpg

 

Flip the panel face down and trace the outside edge of each panel leaf and the rectangular cutout above it. Do this on both sides. The pencil marks will act as both an alignment guide and a "border" that will show you where you want (and don't want!) glue applied.

 

panel-back-1.jpg

 

When you're done, the panel should look like this:

panel-back-2.jpg

 

Now you can get the two 18mm parts that make up the "brow" built.

 

panel-brow.jpg

For mine, I glued and pinned the parts together. I used pins on the back side so there won't be any pin divots to fill in later.

 

Attach the brow to the top edge of the instrument panel by using glue & apply fasteners from behind. (you get a nicer look that way).

panel-attached.jpg

 

Slide the forward section back so that the notches in the vertical monitor support engage the two vertical cockpit tub sides.

 

TADA!

 

controls-installed.jpg

 

Paint to taste, make jet noises as required. biggrin.gif

 

g.

Proud owner of 80-0007.

http://www.f15sim.com - The only one of her kind.

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that looks fricking awesome. can. not. wait. :pilotfly:

skunk160 | Win10 PRO 64bit | i7-4770K 3.50 GHz | 32GB DDR3/1866MHz | GIGABYTE GeForce GTX 1080 x2 | Oculus Rift S | Virpil MongoosT-50CM2 | Virpil F-14B grip | Virpil 200m Curved Extension | PointCTRL | Delta Sim TM Slew | Sim Bandit AHCP | MFG Crosswind Pedals | //FOX2 Switch Boxes | RECARO SPG Seat | AuraSound AST-2B-4 Pro Bass Transducer x2

//FOXTWO Multi-Role Combat Pit Build http://forums.eagle.ru/showthread.php?t=134745

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I've asked a friend for the FS paint codes used on the interior of the A-10C tub.

 

I'm going to prime it using paint I've had tinted Zinc Chromate Green. It turned out really nice when I used it on the 109 cockpit. I need to spend some time getting a proper paint booth set up first though.

 

g.

Proud owner of 80-0007.

http://www.f15sim.com - The only one of her kind.

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Cheers Gene

 

610 mile round trip :pilotfly: ...totally worth it

 

IMG_7972.thumb.JPG.0863bc01dac8665fa109f9de0e4cb986.JPG

skunk160 | Win10 PRO 64bit | i7-4770K 3.50 GHz | 32GB DDR3/1866MHz | GIGABYTE GeForce GTX 1080 x2 | Oculus Rift S | Virpil MongoosT-50CM2 | Virpil F-14B grip | Virpil 200m Curved Extension | PointCTRL | Delta Sim TM Slew | Sim Bandit AHCP | MFG Crosswind Pedals | //FOX2 Switch Boxes | RECARO SPG Seat | AuraSound AST-2B-4 Pro Bass Transducer x2

//FOXTWO Multi-Role Combat Pit Build http://forums.eagle.ru/showthread.php?t=134745

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FIGHT ON!!!

IMG_7978.thumb.JPG.14e7af93ef717f6ce609294a683df510.JPG

IMG_7977.thumb.JPG.690100ee911abffcc3255f983dade8a8.JPG

skunk160 | Win10 PRO 64bit | i7-4770K 3.50 GHz | 32GB DDR3/1866MHz | GIGABYTE GeForce GTX 1080 x2 | Oculus Rift S | Virpil MongoosT-50CM2 | Virpil F-14B grip | Virpil 200m Curved Extension | PointCTRL | Delta Sim TM Slew | Sim Bandit AHCP | MFG Crosswind Pedals | //FOX2 Switch Boxes | RECARO SPG Seat | AuraSound AST-2B-4 Pro Bass Transducer x2

//FOXTWO Multi-Role Combat Pit Build http://forums.eagle.ru/showthread.php?t=134745

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Kudos to you both!

 

Kudos to Jedi and GeneB:thumbup: I haven't done anything yet but drive to pick it up and slot what i can together :joystick:

IMG_7979.thumb.JPG.81d799a98f819286a2a4339b030bcd2b.JPG

skunk160 | Win10 PRO 64bit | i7-4770K 3.50 GHz | 32GB DDR3/1866MHz | GIGABYTE GeForce GTX 1080 x2 | Oculus Rift S | Virpil MongoosT-50CM2 | Virpil F-14B grip | Virpil 200m Curved Extension | PointCTRL | Delta Sim TM Slew | Sim Bandit AHCP | MFG Crosswind Pedals | //FOX2 Switch Boxes | RECARO SPG Seat | AuraSound AST-2B-4 Pro Bass Transducer x2

//FOXTWO Multi-Role Combat Pit Build http://forums.eagle.ru/showthread.php?t=134745

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  • 1 month later...

Nice!

 

ill back on mine next week. I got galvanized decking right angle brackets tying the front section together, machine screws thru the ply into T-nuts on the hidden side.

 

looking good G

skunk160 | Win10 PRO 64bit | i7-4770K 3.50 GHz | 32GB DDR3/1866MHz | GIGABYTE GeForce GTX 1080 x2 | Oculus Rift S | Virpil MongoosT-50CM2 | Virpil F-14B grip | Virpil 200m Curved Extension | PointCTRL | Delta Sim TM Slew | Sim Bandit AHCP | MFG Crosswind Pedals | //FOX2 Switch Boxes | RECARO SPG Seat | AuraSound AST-2B-4 Pro Bass Transducer x2

//FOXTWO Multi-Role Combat Pit Build http://forums.eagle.ru/showthread.php?t=134745

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I went the minimal route - I used 1 x 1/2" L brackets in the spots where the greeblies increased the thickness of the material so the stock screws wouldn't pass through. In other spots I used very thin L braces and used #6 3/8" screws for those.

 

There's a 15" LCD behind the Cougar MFDs being held in place with some custom brackets I printed. At some point I'll attack the seat back with a spray gun and get the interior painted.

 

g.

Proud owner of 80-0007.

http://www.f15sim.com - The only one of her kind.

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