Universal military aircraft homecockpit project

[Viper1970]

The F-14 handles. I slipped them over the rest of the WH-levers (after the original handles were cutted off) and fixed them at the right position with super glue. Only the big part of the lever is fixed, the small cover not, cause it should stay removeable. In this way it's mostly like the original handles also.

After the fix at the right position, I disassembled the whole throttle again and made holes for screws that go through the whole handle and the lever. Here you must take care to not drill through the wire duct of the levers cause there is no other way to transfer the cables, as inside of this duct.

The inside mechanics, which do the spring loading of the original detents (the AB detend, filed down is still in use on all my throttles, except the A-10), must be cutted a little bit (something arround 8mm) to avoid a collision with the screws. But this makes absolutely no difference in the function of the springloaded mechanism.

The covers of the levers are still removeable. You must remove the two screws which go through the whole grip and the lever and also the two original screws at the bottom. After this you can slide them downwards out of the grip. I will add some epoxy to the corners where the big levers go into the handle also, but not much. The whole thing is already stable as hell.

The levers and grips at the Hornet throttle will be done in the same way.

P.S: The original small holes I made in the 3D construction aren't used, cause at that time I was of the opinion that the cables are routed centrally in the lever. Don't know why?

No idea how I came to this, because I had even looked at photos of the disassembled lever. Probably I have it then, when I have made the construction, had wrong in memory. <profanity> just happens sometimes. But I didn't want to design and print new handles now.

 

Edited July 5, 2022 by Viper1970

[Viper1970]

Everything fits in! But it is really brutally tight in the Tomcat handle. And the wiring for the diagonal direction of the 8way POV, used on the second small outside hat for its own directions, needs a lot of cables.

In the Hornet handle, everything will be much easier (hopefully).

 

 

[Viper1970]

Made a mistake in the planing of the wiring. To use only the diagonals of the 8way hat for the second hat, I had to use diodes. Now everthing is working fine and the throttle is ready for doing the final paint work at a later time. The electronics do not look very nice and a PCB with a circuit for the diodes would be more professional, but it works.

I will now switch to the Hornet throttle and base electronics.

After this I will take a second look again at the Eagle's throttle base and maybe also change some more settings in the base to better fit the functions that I want to have. Now after the Tomcats throttle, which need a lot of changes in the base, I have no more fear to desolder and change more switches at the base-PCB's. 

 

Edited July 6, 2022 by Viper1970

[Viper1970]

I am currently still fiddling around with the throttle bases. The only throttle that is really fully functionally complete is the one of the F-14D.

For the A-10A/C, the F-15C/E and the F/A-18C/E I am still selecting the appropriate functions in the base. Since I'm not rebuilding an original cockpit, where you simply reproduce the functions of the original, I have to set up everything so that it makes sense in the end in conjunction with the rest of my cockpit, but is also not too far away from the original.

This sounds easier than it is and was already with the predecessor of this cockpit the part that has devoured the most time. This will be much more complex at the consoles and panels than it is with the throttle bases, but I have to consider this already, although the functions of the consoles are not even a 100% fixed yet. They are already roughly planned but will certainly also change again during construction phase, cause some things will only then be recognized as a planning error.

I have to make compromises also of course, like some switches in some airframes will not be at the right places in the cockpit and some things will only be operable in the virtual pit, but otherwise it's just not feasible to do a universal usable pit.

And in addition, even with expensive HOTAS like the WinWing Taurus, the switches are partly on the wrong side of the cockpit and that's only made for one airframe, not to mention the generally usable HOTAS. There is nothing right anyway.

I know some guys think this is neither one thing nor another, but I could never commit myself on just one airplane or helicopter. I wanted to be able to fly as many things as possible, but still sit in a cockpit and have the feeling of real switchable buttons and switches.

 

Edited July 8, 2022 by Viper1970

[Viper1970]

This is the way I make 3D parts.

The example here is the A-10 Air Refuel Door Lever. Starting with simple shapes, putting them together to match the shape of the lever from top. After this I cloned this shape, turn it 90° and reduce the high to match the top-view part.

Then I take a cuboid and put it over and lay it over the turned and reduced in height part. I make this part a negative part and substract it from the cube.

Now the cube will be put over the first part I made out of the simple shapes. This time the cube must changed to negative and substracted from the made part.

After this I have a part which already looks very similar to the part I want to have. Now the whole thing must be exported and put into Meshmixer. The first thing I do here is to remash the part with a finer mesh.

Here I used "adaptive density", cause it makes the part already more smooth while the remaeshing process. If you don't want this and keep some sharp corners use the "linear subdivision" method.

After the remashing I did a mesh smoothing. Here you have to experiment with the settings until you are fine with the result.

This is the way I did also all my HOTAS. It's not the professional way to make 3D models, dirty but quick!

For further reworks like making holes etc. you have to reimport the model to TinkerCAD again. But you have to keep in mind, that the polygons to reimport it do not have to be over 300.000 polys.

It's also often that after the reimport some cracks appear in the model, but after another export of the final model you can repair and smooth the part again with Meshmixer.

But only smmoth those surfaces that have no fits, cause if you smooth the whole model, those fits will also be smoothed.

P.S: This part took me arround 5 minutes of work. After the rough shape is done you can anytime change the dimensions, like height, lenght, wide and so on.

 

Edited July 8, 2022 by Viper1970

[Viper1970]

Just seen I have still a fully functional, not disassembled Suncom SFS Throttle. I will mod this one to a universal useable throttle for single and dual engine jets, like the F-104, F-4, F-8, A-7, A-6, A-4 or even trainer aircraft like the T-45, the L39 and so on.

The Suncom SFS has an easy to use lock mechanism between the throttles and if this mechanism is greased properly it works very well. In my opinion it is much better as the lock on the Warthog (I removed at all my throttles ). In this case I will leave it, to be able to use it for dual or single engine jets.

This will be a MMJoy2 project. It will get two "antenna-wheels", a slew and a few buttons. Not as much as the other throttles, cause it should be used mainly for older fighter jets or trainers. There is a MASON throttle, that is designed like that and is also in two versions available, single- and dual engine, but the grip itself is identical, except the dual-engine version is splitted into two halfs. This one will get a satin white or light grey color.

Edited July 10, 2022 by Viper1970

[Viper1970]

I took a break for two days, because I couldn't see any throttle anymore.

Doing the same thing four times gets on my nerves and when something starts to annoy or bore me, I start tinkering. Therefore rather a break.

Now the base of the Hornet throttle is finished. Tomorrow I'll do the wiring in the handle, then the thing should also be functionally and electronically complete. Some smaller spray-paintings and / or the lettering must still be done everywhere.

Actually I wanted to continue with the twist-grip for the collectives, which use this system, but then I had the idea of this "universal" throttle. I think I will add that.

At the Harrier is not much to spray paint on the base and also not the Osprey throttle, the grips are already done, so that should still go out in time this summer.

Edited July 11, 2022 by Viper1970

[Viper1970]

Hornet throttle functional ready. Paintworks on the switches, buttons and other details and also the lettering on the base-plate will be finished at a later time at all throttles. Still looks ugly at the moment.

The rotary knob is for the rudder trim. The button next for the take-off trim. The real Hornet has this combined, but I made it this way cause it's easier to do and more stable. It's no pot, only a springloaded, selfcentering dial-switch. I did it the same way at my A-10 throttle. The autopilot panel is in my consoles, so there is no need for it at the A-10 throttle.

The flaps switch at the Hornet throttle is removed and changed to a 2way for the APU. I have the flaps switch in the panel for the Hornet. The two 2way switches in the autopilot section changed to a 3way momentary switch in both directions rotated 90° for the engine crank.

Not all is on the right place, like in the real plane, cause this is impossible to do with a modded WH throttle, but the grips at all throttles are mostly functional like the real thing. The antenna up/down wheel is springloaded and selfcentering at this throttle and I used the friction pot for it.

The fingerlift mechanics will also be changed to a darker look later. But all those works could also be done after the summer, including the grey painting of the sides of the base housing.

Now I will start with my "universal" throttle and after this with the twist grip of the collectives.

A-10 and F-15 throttle grips must still be spray painted. I will do this the next days between the other work.

After this all grips, handles, collective-handles and so on, in short, everything you hold in your hand is then already painted satin black.

Some HOTAS need a lettering at the grips also and all HOTAS grips will get a final satin clear coating. This is the work I would like to finish until the end of September.

 

Edited July 12, 2022 by Viper1970

[_Hoss]

Viper, you can have custom plates made for your throttle from Tek Creations, he will send you a blank and you can design it how you want it. This the one I'm working on for IL2 and DCS Warbirds. 

Spoiler

 

[agrasyuk]

19 hours ago, 352nd_Hoss said:

Viper, you can have custom plates made for your throttle from Tek Creations, he will send you a blank and you can design it how you want it. This the one I'm working on for IL2 and DCS Warbirds. 

  Hide contents

 

I think Viper has capacity to produce his own face plates. 

 

 

Viper, I don't want to poop on your amazing universal project, but I think that once you start flying you may found out that you only interested in 1 - 2 airframes the most... I'd offer to start spending time in various planes. This will help you prioritize and better understand what needs to be built to the T, what corners can be cut.

 

Let me know if you want to fly together some time. 

[Viper1970]

21 hours ago, 352nd_Hoss said:

Viper, you can have custom plates made for your throttle from Tek Creations, he will send you a blank and you can design it how you want it. This the one I'm working on for IL2 and DCS Warbirds. 

  Reveal hidden contents

 

Thanks, that's a good advice! But I will make my own plates, cause I have to do all the plates for the consoles as well anyway. My Warthog will also no longer have lighting, as I will be lighting my entire consoles, as well as the throttles from above my cockpit sidewall. There are then green, white and also UV-LED's installed, so that in the dark the white writing looks somewhat fluorescent.

[Viper1970]

1 hour ago, agrasyuk said:

I think Viper has capacity to produce his own face plates. 

 

 

Viper, I don't want to poop on your amazing universal project, but I think that once you start flying you may found out that you only interested in 1 - 2 airframes the most... I'd offer to start spending time in various planes. This will help you prioritize and better understand what needs to be built to the T, what corners can be cut.

 

Let me know if you want to fly together some time. 

Yes I know the whole thing is a very over the top project, but I really can't settle on one airframe.

I've always liked the whole Ten-Fighter series, F-14, F-15, F-16 and F/A-18, and the A-10 and AV-8B. Those were the jets I really wanted to fly simulated and waited years to finally have them all on the same level in a simulation. Whereas the F-14, there however then the D-model, is my favorite among the jets.

For the helicopters, it's actually the AH-1F Cobra, but unfortunately we don't have that yet. Then actually comes the Kiowa and the Apache only afterwards. Initially, I didn't like it at all, because the A-model has displaced my beloved Cobra. I still feel the same way about the Super Hornet, which has killed off the F-14D.

I already had the universal cockpit concept in my first attempt in 1998. Of course, back then everything was much easier to implement because the complexity of the simulations was not nearly as high as it is today.

But even back then people were rebuilding F-16 cockpits and I always thought to myself, yes that's great, but always flying the same airframe would be too boring for me in the long run. And if I'm going to go through the trouble of building a pit, I want to be able to use it in a more versatile way. That was the start of this project.

I already had five pits more than half-finished, but unfortunately could never complete them for reasons in RL. It was less because of the implementation, but because of time, finances and other serious things in my life and partnership.

This time I would like to simply fulfill this dream, which I have been carrying around with me for almost 25 years now. Time I have now, money, well not very much, but ideas.

 

And yes, of course I'd love to fly with you anytime, once the thing is reasonably usable. Right now the plan is to have at least the F-14 somewhat operational by the end of the year.

 

 

[_Hoss]

Good on ya then..... keep posting progress

[Viper1970]

The universal throttle is also mostly made mechanical wise. I droped the idea of printing grips after the MASON throttle I mentioned and modded the grips of the Suncom SFS throttle instead to make them appear more "universal" instead of looking like another F-15 throttle. I did this the old fashioned way I also did it back those days, I had no 3D printer available. Using other parts of throttle shells, adjusting them in shape and adding them to the grips with epoxy. I also used all the buttons and switches I had lying arround and have no real use for them.

In the end, it doesn't matter if it exists in real life or not, it's supposed to be universally usable and only look somewhat "real". The big advantage of the Suncom throttle is the proximity of the two handles to each other. They are so close to each other (unlike the Warthog and also the real F-15 throttle) that you can also use it as a single engine throttle, when it is locked. It will also get fingerlifts and I have to look for a solutions for a deactivable AB detent. Maybe a solution with magnets, like some guys did it on the TWCS.

I will also post pics of it if there is more to show. At the moment it's very prototypical.
It will be fillered and primed, when I paint the grips of the A-10 and F-15 throttles also.

Edited July 13, 2022 by Viper1970

[Viper1970]

So, the last one of the fighter throttles nearly ready for fillering, sanding and priming. Only some switches in the base are missing.

I will do all three remaining throttles (A-10, F-15 and this one) in one paint session the next days.

The AV-8B has also still to be made, but I use a little wooden box for this as housing and also for the the MV-22B throttle. Only the mechanical parts, the nozzle lever and the lever arm of the AV-8B are printed. The rest is from canabilized TWCS. Those parts will be painted in the flat without the use of spray cans. Finally the base boxes wont look like wood anymore, but those boxes had the right dimensions I needed for those throttles and so a bought them together with the boxes I use for my consoles.

The base of this Universal fighter throttle will get a gray which is very near to the one in US fighter jets. The "plate" will be satin black. (this will be identical at all my HOTAS). But the throttle itself will be painted light grey, like the F-14D throttle. Fingerlifts, buttons and hats will be black, the two wheels dark grey and the slew and the boat switch light grey. All will be fired by an Arduino Pro micro with the use of MMJoy2. It will use 6 axis and 18 button functions including the base finaly. I must use a button matrix for this. The antenna wheel on the left has a center detent pot, the other one a normal pot. The slew is a thumbstick with a pushbutton.

All eight throttles will get the same metal plate at the bottom, for which I will do a quick mount in my left console. I use the original WH throttle base metal plates for this. I will only use one of them at each throttle and so I have another four plates for the other throttles, like the Cougar, the Harrier, the Osprey and this one. The Apache throttle (also made out of an old Suncom throttle) will get a plate with the same dimensions, to also be mounted at the throttle place.

 

Edited July 14, 2022 by Viper1970

[Viper1970]

The universal "vintage throttle".   Base is still not ready painted and a lot other things also missing.

 

[Thadiun Okona]

Bumping this in case viper thinks there's no interest since he mostly posts alone here. This is one of the more interesting threads around here though, love seeing all the progress

[Viper1970]

Thank you!

I'm still here, but I also need to pay attention to my wife again. Without her support and tolerance towards my hobby, so much would not have been possible in the first place.

After I have now worked almost one and a half years without interruption on the project and have almost reached my partial goal by the end of this year, only a few parts still need to be painted this summer, the rest will have time, I will now spend a lot of time with her again.

It's great to have such a partner and anything but a matter of course, I know that only too well. Therefore, I would now like to do more together with her again.

But the project is far from over, it will continue.

[Uxi]

Definitely interested in seeing more of your wing sweep cover and mechanism.  

I'd be inclined to go with a momentary hinge metal roller lever micro switch for the cover more than a push button but either way. 

[Viper1970]

After some wonderful weeks now with my wife, I'm slowly coming back to the project. There is still sooo much to do and there were also so many new modules announced in the meantime that have always interested me and that I would also like to use with my cockpit, like the C-130J, the F-4, the F-8, the A-7 and of course also the A-1H!

Only thing I'm still missing is an announcement of an AH-1F Tow Cobra, my all time favorite attack helicopter. If this will also come true somewhere in future, I will never need any other simulation beside DCS.

[agrasyuk]

Do you really need an announcement?

By the the time we finish our projects I'm sure many more modules will see light of day )

[Viper1970]

On 9/24/2022 at 2:04 AM, agrasyuk said:

Do you really need an announcement?

By the the time we finish our projects I'm sure many more modules will see light of day )

Yes, I know. But I still miss the AH-1F a lot in the list, especially since we get so many other flying legends now, the former workhorse of the Army, before the days of the Apache, is really still missing.

And as far as I know they already started to work on it, before Belsimtek and ED went together.

Edited October 3, 2022 by Viper1970

[Sierra99]

Viper1970 I apologize but I am arriving at this party late. Are the files for these sticks and throttles available for download someplace?

 

you are doing amazing work.

 

Sierra Sends. 

[Viper1970]

Not much going on here the last time, cause RL has cought me again. But the project isn't dead.

I hope I'm back on the track again at the beginning of next year.

Meanwhile only very few smaller progresses have been done, which aren't really worth mentioning.

If something interesting happens again, I will report further and also show photos of the new results.

[Viper1970]

Just got my hands on two TCA Boeing Throttle Quadrants very cheap (two under the price of one ). So I don't need to print the 4 Engine Qudrant for the big birds like the C-130J completely by myself anymore, which would have been a big piece of work.

Now I only need to integrate a trim-wheel to this double pack, which I print myself. After this most of my inputs are ready for doing the electronical stuff like integrating all the POV's and switches. I also got my hands on some more old TM FLCS & TQS, which will spent their POV's to all my HOTAS.

I am currently planning how to make 5way POV's out of some of these POV's as well, in which I still make a pushbutton micro switch switchable on the axis of the POV. This would also save some work instead of printing all POV's completely. So the project slowly goes further.