PROJECT OVERVIEW

To replicate a Boeing 737-800 flight deck to use within the simulator environment using Original Equipment Parts (OEM).

Clearly, not every OEM part can be used in a simulator.  Therefore, where an OEM part cannot be used, a quality high-end reproduction will be used in its place.

Project Time Line

There is no time-line established for the project.  Project research began in early 2011.

Completion is dependent upon the availability of OEM components, and the time available for conversion and construction. This project is viewed as a long term project; a staged approach has been taken (Research and Development).

Reason for Website

The reason for this website is two-fold.

First, it is to cement my thoughts and document the methods used during the development and building process.  In essence, a 'dear diary' explaining how and why I came to the conclusions I did.

Second, I hope this website will provide information, ideas and inspiration to individuals tackling similar projects.

The website will document the progress of the build in addition to providing information pertinent to the Boeing 737 and flight simulator.  Reviews will be published on various parts and software used in the project.

The website will be continually in a state of flux as information is added, amended, and reviews completed.

  • There is a vast amount of information on this website.  Some of the information is now dated, or refers to parts of the simulator that have been superseded.  Rather than delete the earlier articles, I have left them for information and completeness.

Scientific Method & Repeatability

The definition of Scientific Method is 'A body of techniques for investigating phenomena, acquiring new knowledge, or correcting and integrating previous knowledge'.

Building a simulator is not an individual effort.  It is group effort that replicates and builds upon the knowledge and expertise of others.  Therefore, while I will be designing, building and implementing some items, I will also be using the services of individuals more knowledgeable than myself.

To those individuals that have helped me, I offer my sincere thanks.

Which Flight Deck to Simulate ?

This can be a difficult question to come to grips with, because once you select an aircraft and begin construction, there is little scope for alteration.

Two areas dictate the aircraft simulated: the avionics suite (Sim Avionics or ProSim737) and the availability of OEM parts.

At the time of writing, the Boeing 737-800 aircraft was the only airframe that fitted these requirements.

OEM (Real Aviation Parts)

Rather than use reproduction parts, I wanted to use real aircraft parts (OEM).   Fortunately, Boeing in their infinite wisdom of 'saving money' use, in the Next Generation, many parts that are identical to, or have evolved from, parts used in the classic series airframe.  As such, this parts are quite often available second hand.

For a complete list of OEM parts used in the simulator, see the section 737 OEM.

This said, compromises must be made.

For example, to purchase an OEM 737-800 Next Generation throttle and pedestal at the time of writing is cost prohibitive.  Therefore, an OEM 737-500 throttle and center pedestal was purchased and converted to ‘appear’ very similar to the Next Generation throttle quadrant.  To a purest, it’s not 100% perfect, but it is very very close.  Whatever is said, using a real 737 throttle that has been retro-fitted to appear similar to a NG type is 'eons' ahead of using a reproduction throttle.

The same can be said with instruments, avionics and panels (aka modules).  There are several companies that manufacture quality panels, but you can’t match the realism, appearance, and immersion of an OEM panel or gauge.  Using an OEM gauge is literally 'as real as it gets'.

I can’t explain the satisfaction felt, when you grasp real throttle handles and peer intently into real gauges, and pull back lightly on a real yoke during takeoff.  It’s exciting to think, that the parts once graced the skies in some far away land.  Yes it’s a romantic image.

It’s also a good feeling knowing you are recycling an old airline part destined for the scrap yard, rather than purchasing something new from finite resources.

Level of Realism -  Aesthetics, Functionality and Immersion

This is, and always will be, a contentious issue. How far do you go to replicate and simulate a real aircraft.  Replicating a fully functional 737 flight deck is possible, but it comes at the cost of a large financial and time outlay. 

Flight simulation in many respects is about compromise; it is not necessary to replicate every last screw on a flight deck.  Aesthetics is important, however, it should not trump functionality.  I believe that I have reached middle ground in the design of the simulator.

At the beginning of the project, I decided not to replicate the 737 flight deck in entirety. I wasn't interested in constructing a simulator rivaling those used for pilot certification at UPS, FED EX or Boeing; to do so would be space and cost prohibitive.

I did, however, want a level of immersion that was beyond that offered by a standard generic style desktop simulator.  Therefore, anything fabricated had to be done as realistically as possible with a high attention to detail. 

First and foremost was an accurate simulation of the aircraft systems, if possible interfaced with OEM parts and panels.  This ethos supplanted replicating a full-scale flight deck that looks pretty but has limited functionality or is made solely from reproduction parts.

Immersion Level

The words realism and immersion often go hand in hand.  Realism refers to using OEM parts and panels, and immersion is making the person flying in the simulator, believe that they are somewhere else, or in another place and time.

Immersion is a mind manipulation process called 'suspension of disbelief'.  It’s a phenomenon where the occupant of the simulator stops thinking they’re located in a home setting, and starts believing that are in a real aircraft flying somewhere over Europe or elsewhere.  It could be likened to a type of hypnotic effect. 

Immersion is the term used to describe the depth to which this belief intensifies.  Without this hypnotic effect, the simulation would appear very game-like and unrealistic.  The use 3D is a classic use of the immersion effect.

My Musings - OEM verses Reproduction

A simulator falls within three spheres:  To the left there is a full simulation which for all intensive purposes is difficult to separate from the real aircraft (other than it's inside your house!).  Opposing this is the desktop simulator.  Riding between the two is a set-up, which most people end up achieving to a lesser or greater degree.

Not wanting to argue with those riding the left wave, a simulation is not a real aircraft, but a simulation.

It is more productive to develop what appears to be a quality simulator (that looks like a simulator) rather than replicate a half-made nose cone which does not stand up to scrutiny. Therefore, the emphasis will be using OEM components and replicating real aircraft systems in a simulator-style environment.

Modular Approach

I believe the Scandinavians were the first to capitalise on the modular approach with the building of home furnishings.  In Australia, IKEA promotes their 'flat pack style of furniture' that can be put together using basic tools (a spanner and a screwdriver…).

The modular concept is a very good idea, especially when you have complicated systems that inter-finger with each other.  Many enthusiasts install interface cards wherever they can be mounted, and often what eventuates is a rats nest of wiring without method. 

The interface cards needed for various panels and parts, will be installed to a dedicated module called an interface module.  Each module will be specific to one or two like-minded aircraft systems.

For example, the Throttle Interface Module (TIM) will accommodate the interface cards and wiring relating in the operation of the throttle quadrant.  Another module, named the Overhead Interface Module (OIM) will be used for interface cards, USB hubs and other paraphernalia  specific to the forward and aft overheads.

The modules will be mounted forward of the Main Instrument Panel in a dedicated shelf.  Connection with the simulator will be by straight through cables, Ethernet and USB.

Using a modular system will keep liker-minded systems together, and aid in troubleshooting and promote ease of maintenance.

More can be read concerning each interface module in the appropriate section.

Compromise - There has to be a Limit

There must be a compromise, and unless wanting to spends upward of $100 K for a turn-key reproduction flight simulator, trying to achieve the maximum level of realism and immersion will stretch your budget to breaking point.  Therefore, compromises have been made in some areas; there has to be a time when you say 'enough is enough'. 

At the beginning of the project, the MIP, supplied by Flight Deck Solutions became the central point in the flight deck.  To this MIP, as they became available,  OEM parts and panels replaced reproduction items.  The advantage of using a prefabricated MIP at the beginning of the project, was that I could fly the simulator during the building process.  This meant that I didn't loose interest.

Yes, you can have everything working to the tenth degree, but it will take an inordinate amount of time to do this.  It will also require a relatively high level of technical skill, and patience to troubleshoot and fine tune, until everything works as it should.  Additionally, you’ll also have to maintain what you have done, to ensure continued operation (more on this later).

It’s an unfortunate fact that most of us have real jobs and real lives and don’t have the time to allocate to such an undertaking.  Furthermore, the conversion of some OEM parts is not feasible: technical knowledge, time constraints and lastly patience all play a factor.

Importantly, it’s wise to remember that the simulator is used to mimic flight, and if you spend your time continually building you will quickly forget how to fly.  Worse still, your project will never exit the construction stage.

Scope Creep

'Scope creep' is a term used in consultancy meaning that a project becomes larger and larger as time progresses.  This project is not immune; as parts of the project are completed, new areas open up.  Although creep in itself isn’t bad, it must be kept an eye on; it’s easy to let the project go beyond what either you are capable of doing, or able to outlay financially.

Evolution

Technology is not static, and improvements in computing and interfacing occur regularly.

What was considered advanced in 2011, is in 2020 considered obsolete.  Not so long ago, it wasn’t possible to interface an OEM part without going through a considerable conversion process.  Today, there are a number of specialist cards that use ARINC 429 to communicate between OEM parts and ProSim737. 

By far the biggest development over the last few years, has been changes in how the throttle quadrant is interfaced.  In 2011, I was using one power supply, an inexpensive motor controller card, and sail servos to control a throttle quadrant removed from a 737-300 airframe.    At the time, the software was incapable of generating automation that could be considered reliable, with a consistent output.   Calibration was also rudimentary and the wiring ‘dodgy’; thinking about it today, it’s amazing it worked at all!

Compatibility

There are a dozen or more companies that produce replicated parts and panels, and each uses it's own propriety system to interface with ProSim737.  It's not recommended to mix panels with differing communication protocols with each other.  While mixing some panels from one company with another will work, other combinations won't work.  Therefore, at the beginning of a project it's wise to try and center your selection around those companies whose panels can be used interchangeably (or stay with one company).

If converting OEM parts, it's wise to select an interface and communication protocol that is well established, has been used widely, and perhaps is open source.  Doing so will protect you in the event that a company that uses propriety software ceases business.

Maintenance

Whatever system you purchase or build, there will become a time when it doesn't work.  It could be a failure of a part, interface card, loose wire, or changes to the computer operating system (WIN10 updates can and do create problems).  Therefore, only build or use what you can service yourself; maintain the KIS ethos (Keep It Simple).

Time, Frustration and Patience

Time is finite and valuable and I have other passions in addition to flight simulation.

Therefore, rather than construct a Main Instrument Panel (MIP) from scratch (OEM MIPS at that time were unobtainable), a commercial fully integrated MIP was acquired from Flight Deck Solutions (FDS) in Canada.

This saved me considerable time, and the MIP became the skeleton that the simulator was created around.  Now (in mid 2020), nearly everything on the MIP has been replaced with OEM parts, and I’ve no doubt that in time, an OEM MIP will be procured.

One aspect of flight simulation that is often difficult to grasp is patience.

Everything seems to take an inordinate amount of time.  Not too mention that manufacturers and suppliers are often small scale operators that cannot deliver overnight; larger companies even seem to have excessive delays in supplying their products.

When I was in the military, I was told patience is a virtue (or something to that effect with a more colourful vocabulary).