Cessna 172 Cockpit - Your Dream Flight .

10/09/2016
Cessna172CockpitYourdreamflight...
MyDIYCessna172Cockpit
Workinprogress.Updatedeveryday.
Content:
Dimensions
Thepanel
Rotaryencoders
Knobs
Bezels/Screws
Decals
Switches
Theyoke
Throttle/Mixture
TrimWheel
PMGAIFR
Arduino/Link2Fs
Rudderpedals
Radiostack
GPS
Pricelist
Video
Alldownloadsinoneplace
In this page i will try to document my work on the Cessna 172

cockpit i'm building, which may help someone trying to build the
same. Even if not the same, you might get ideas for some of the
components. For this project I'm using as much DIY as i can to
spend less money. Until now it has cost me around 80 Euro (not
includingsomepartsialreadyhad).Itisnotfinishedyetbuticanfly
withit.The22inchesmonitorlookstoosmallbuti'mfocusingonthe
cockpitfornow.Ihave2x22inchesmonitorstoputinfrontandlater
i'm planing to use one projector and 2x22 inches monitors on the
http://flyingforfun.weebly.com/cessna172cockpit.html
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sides. Things to be done: Radio Stack, GPS, Parking brake, Fuel

selectorandfuelcutoffswitch,TrimWheel,Flapshandle,Covering
thetopwithleather,Pedalsinprogress,Projectorsetup.
The idea of the project has begun pretty early but didn't start until
now. This is a hobby so no rush ). I had planed to build a motion
platformaswellbutwewillsee,imightdoitlater.Youcanfindthe
sketchup file in the 3d warehouse if you would like to download it
andtakealookatit.Ihadplanedtobuildthemotionplatformfrom
wipermotorsbutimightchangethataswell.
Cessna172simulatorsketchup
Dimensions
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Whenistartedtheprojectiwantedtomakea1:1cockpit,soifound
somemeasurementsthatsomeonedid(idon'tknowtheauthor)and
triedtoapplythosemeasurements.Ontherightsideyouhaveonly
4 pictures but you can download all of them (44 pictures) below.
SinceihaveneverbeeninaCessnaCockpit,thiswasagreathelp
togetasenseofthesizeofthecockpitandcomponents(thecabin
isprettysmalllol,only1m).
Cessna172Dimensions.rar
DownloadFile
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Thepanel
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obuildtheMainpanel,LowerpanelandtheGelarshield,ichoose
T
4mmAlucobond(youcanchoosedifferentmaterial).Alsocommonly
referred to as "Diabond" or "ACM", aluminium composite panels
consist of two aluminium cover sheets and a core made of low
densitypolyethylene.Itislightweight,weatherresitant,unbreakable,
shockresistant, vibration absorbant and easy to install. It is at the
sametimestableandyetflexible.
In addition, aluminium composite panels have a smooth glossy
surfaceandareavailableinanumberofstandardcolourswhichcan
reducetheneedtopainttheproduct.
neotherreasonIwentwiththeACMwasthatihavesheetslaying
O
around in two colors, the perfect ones for the cockpit. I found a
Cessna1721:1Paneldrawingontheinternet(youcandownloadon
the right side the original version) but I had to modify it. I modified
thegaugessize(madethemsmallerwhichhelpedmelaterwiththe
bezels)andseparatedthewholepanelintwoparts:MainPaneland
Lower Panel (for the lower panel i used black alucobond). I also
deletedtheRadioStackandGPSpanelandwillcutthemlaterwhen
iwillbereadyforthem.Youcanmodifythepanelthewayyoulike
it.ThecreditoftheoriginaldrawinggoestotheAuthorwhichifound
onmycockpit.org.
Cessna172originalpanel.dwg
DownloadFile
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Cessna172OriginalPanel
DownloadFile
SinceihaveaCNC,IexportedthedrawingtoArtCamandmadethemodificationsthere.Youcandothemeitherin
AutoCadorArtCam.OntheleftsidebelowyouseethatIhavemirroredthepanel,soicouldopenchannelsforthe
rotaryencoderwires.Asisaidihavemodifiedtheseinartcamsoionlyhavetheartcamfilesifanyonewantstohave
them,youcanfindthembelow.
MainPanel.art
DownloadFile
LowerPanel.art
DownloadFile
Onethingyoushouldkeepinmindisthat,beforebuildingthepanel,youneedtohavethemonitorforthegauges.
Thiswayyoumeasurethesizeofitandmodifythepanelbeforecuttingsothemonitorfitsinsidethepanelandyou
don'thavetocuttheGlareshield.Mygaugesscreenis22inchesandididmeasureitbutdidn'twanttohaveittofar
to the right because of the radio stack and gps that i will add later so a tiny piece of the monitor is left on the left
uppercornerofthepanelandihadtocuttheglareshield.Ididthisbecauseiwasgoingtocovertheglareshieldwith
leatheranyway,buticouldeasilynotdothatasitlooksgreatevenwithoutleather(alucobondlooksgreat).Ishould
havemovedthemonitoralittlebittotherightsoididn'thavetocuttheglareshieldatallbutitisalreadydonesoyou
shouldthinkaboutthatbeforestartingtocutthegauges.
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ftercuttingbothpanelswithCNC,ibentthelowerpartofthemain
A
panel and upper part of the lower panel and connected them
together using rivets. I did this for two reasons, to connect them
togetherandtolaythemonitoronthatedge.Theframeasyoucan
seeismadeof20x20mmsquaremetalprofiles.Aluminiumwouldbe
even better or even wood can be used as well. Frame dimensions
are 100mmx40mm and the height to the botom of the panel is
47mm.
Rotaryencoders
(After finishing the frame and attaching both panels, i added the
rotaryencoders.Havingthealucobondpanelonly4mmthick,makes
us find tiny rotary encoders and this made me use Mouse wheel
encoders. You can either buy them as encoders or desolder them
frommice.Ifyougowiththesecondoption,youneedtoknowthat
noteverymousehastheseencoders.Ididn'tpurchasejustbecause
i didn't want to wait for them to arrive but this way i bought used
micelocallyandfoundoutthatfewofthemdidn'thavethem,sothe
firstoptionmightbebetter.Ifyouwanttopurchaseonline,hereisa
link on ebay (didn't purchase myself and don't know the seller but
just found them for reference) Mouse Wheel Rotary Encoders E
bay$2.58for10pcs(youonlyneed6)includingshipping.
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Knobs
Forknobs,ifoundsimilaroneslikethepictureintheleftherelocaly
and paid 5 euro for 6 pcs. If you can't find them locally, there are
plenty of places to search on internet. here is a link on ebay for
these knobs. I used the mouse wheels encoders for : Altitude,
Heading bug, Gyro drift, VOR1, VOR2, ADF hdg. but if you have
moreofthemisnotabadidea,maybeyou'llneedthemlaterwhen
buildingtherradiostackandthegpsunit.
Knobs on ebay $4.50 for 10 pcs (you only need 6) including
shipping.
I used the mouse wheel shaft (cut the wheel) and glued it to the
knob.IgluedtheencodersonthepanelusingCAgluewithactivator.
IusedCAglueonthewiresrunningthroughthechannelsiopened
onthebackofthemainpanelaswelltoholdtheminplace.
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Bezels/Screws
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Tomakethebezelsiusedplasticcups.Therearedifferentones,but
i found the perfect fit for the big gauges. These cups have a
diameterof74mmontheinsideand79mmontheoutside.Theonly
problem was that i couldn't find them in black, so took some blue
onesandpaintedthemblack.Forthesmallgaugesiusedthesame
, just cut a piece out of it and glued them on the panel using CA
glue. To cut them i just put them on the panel and cut them with a
sharpknifefromtheotherside.
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For the screws that hold the gauges in place i couldn't find black
ones locally, so i just bought white and painted them black, drilled
theholesaroundthegauges,cutthescrews4mmlengthandglued
them using CA glue. You could also use nylon screws like in the
picture. If you can't find them locally, search on ebay, there are
plenty of them and pretty cheap. In the pictures below you will see
thebackofthepanelwiththechannelforrotaryencoderswires,and
withthebezelsendscrewsmounted.
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Decals
After finishing with bezels and screws i printed the placards. For the main panel I used transparent sheet to print
them,theniusedtransparentpackingtapetoprotectthewritingsandgluedthemonthepanelwithgluestickandit's
holding until now, you may come up with a different idea. Of course having transparent sticking sheets would be
better,siIwillpurchasesomeofthemfrominternetandreplacetheexistingones.Forthelowerpanel,iprintedthe
decals on normal A4 paper, and put some transparent packing tape on top to protect them. Underneath I used
doublesidedtapesoicouldstickthemtothesurface(becomesthesameaspremadestickers).
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Below are the decals for the main panel and the lower panel. The credit for the decals goes to the author Zahid
SadalfromStttemedlemmeravSimgruppaAvd.SolaFlymuseumgrouponfacebookwhodidagreatjob.Youcan
downloadthemas.psdfileandeditorprintthem.Pleasechangethetailnumbertoyourdesiredone,theoneinthe
decalsisusedbymeDDEDT.F orthelowerpaneliprintedtheplacardsonnormalA4paperandcutthemasclose
aspossibletotheletters,whichwillminimizethecolordifferencebetweenthepanelandthetextbackground.
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MainPanel.psd
DownloadFile
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LowerPanel.psd
DownloadFile
ThedecalsgavetheCockpitanicelook:)
Switches
I purchased the key from ebay. It's a 2 position key (on/off) for
motorcycles and it cost me $1.74 free shipping here is the link.
There are 5 position switches on the market but they are more
expensive, so if you want more realism, you can purchase one of
them.Ondesktopaviatorpageifoundoneforaround$39.Youcan
alsofinda5positionrotaryswitchandusethatasakeyaswell,it
depends on you. I found Bat/Alt double switch and the Avionics
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switch both locally for 0.80 Euro. They both were red with 0 1
numberswrittenonthem.IsandedalittlebitandpaintedtheAltBat
switchredandtheAvionicsswitchwhite.Ipurchasedtherestofthe
switches from ebay (Fuel pump, Bacon, Land, Taxi, Nav, Strobe,
Pitotheat).10pcsfor$1.96freeshippinghereisthelink.
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Theyoke
I found the yoke on ebay kleinanzeigen in Austria for 45 Euro + 5

euroshippingtoafriendofmine.ItisaChproductsYoke.Ifoundan
even better offer, but it was only for pick up and i couldn't get it
(Saitekyoke+throttlequadrant+Saitekpedals+Saitekmultipanel
+ Saitek radio = 150 Euro, i know it's a very hard deal to find,
obviouslytheguywantedtogetridofthem,soalwayskeepeneye
oninternet,whoknowsyoumightbeluckyandfindsuchdeal.)Ilike
the yoke but i had to do some changes. First i had to change the
stock shaft with a longer one. I found a water pipe the same
diameterandopenedthechannelsonbothsidesontheinnerhalfof
theshaft.Icutthewiresandreplacedtheshaftandthenconnected
the wires with servo connectors. I also painted the yoke black with
spray.IprintedaCessnalogoonanormalA4papersheet,puton
topofittransparentpackingtapetoprotectthe
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logo, and put double sided tape on the other

side. The roll axis works great, but the pitch
axis has some problems. It is hard to flare
because of the friction (with the stock shaft as
well),soiwillchangethestructureofthepitch
axis using drawer slides and springs. I found
them locally very cheap, 1.7 euro for two
pieceslikeinthepictureandI'musingthesameslidesforthepedals.Iwilldocumenttheyokemodsinmoredetails
laterwhenfinished.
Throttle/Mixture
For the throttle/mixture i purchased 3 knobs on ebay like in the

picturebelow(youcanpurchasethemhereabout$4.3for3pcsincl
shipping).OntheinnersideIcutapiecefromapencilandgluedto
thethrottle/mixtureknobs.Onthemixtureknobialsogluedasmall
cameracapthatihadandthendrewacirclewiththeinnercircleof
a CD on an aluminium tape, cut it and taped it on the front. For
Throttle and Mixture holder, i used the plastic handle of an old
screwdriverandsinceididn'thaveadremel,iusedmyrechargeable
drill as in the picture below to make those forms. you may find
plasticformsthatlooksimilarsoyoudon'thavetoworkthatmuchto
getthatshape.
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Trimwheel
Tobuildthetrimwheel,ifoundanalucobondcircleihadlayingthere
thatihadprobablycutforaprojecttimeagowhichhadadiameterof
15 cm and i thought i'm going to use that instead of cutting a new
one.ItookanoldPCPowerSupplycableandcuttherubberopen.I
had to be very careful to cut it as straight as possible. Then, using
CAglue,igluedittothecircleandpaintedthewholewheelinblack.
Also opened the channel in the panel where the wheel will be
mounted.Tousethewheeli'mplanningtouseamouse.Iwillmount
ashaftonthemiddleofthewheelandconnectittoamousewheel
(usingmouswheelencoder)whichwillthenbeconnecteddirectlyto
pcusingtheusbport,thiswayiwillspareaninputonmyArduino.
Sincethemousehasthreemoreswitches,i'mthinkingonusingtwo
ofthemforthebrakesandone,wellidon'tknowyet,i'llsee.I'malso
looking for spheres that i could glue to the wheel to make it look
morerealistic.
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You can follow the pictures to see how Installed the trim wheel using a mouse. The wheel is not finished yet, I will
sanditandpaintitagainforabetterlookandwilltrytofindsomespherestogluethemonthewheel.Afterinstalling
thewheel,underFSUIPC>MiscellanousandchecktheTrimoptionnexttoMousewheel.Thiswayyouwillbeable
tocontrolltheelevatortrimusingmousewheel.Ifyouhappentohavethewheelrotatingtheoppositedireciton,you
canfindmouseprogramsoninternettoreversethedirectionofthemousewheel,that'swhati'mdoingmyself.
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ProjectMagentaGAIFR
To display the instruments on the main panel,
i'musingProjectMagentaGeneralAviationIFR
paneldemoversionuntilifinishthecockpit.On
theirwebsitetherearenopricessoyouhaveto
send them a Pricelist/Quotation request. I like
thesoftwareverymuchandirecommenditasit
looks great, is very easy to use and works
flawlessly on my setup. I have found a glitch
with the speedometer but increasing the Max
Airspeed, solves the problem. To download a
demo or to purchase the PM GAIFR software, go to their website (click here) and register (it's free). After you
register,ifyouwanttodownloadademo,gotoDownloadsandchooseGeneralAviationIFRPanelDemosoyouwill
download a demo time limited version, which will give you an idea how it works. If you want to purchase it, go
toPricelist/Quotationrequestandfilltheform.YouwillreceiveanemailwiththequotationfromProjectMagenta.PM
GAIFRcontainsfourtypesofcockpits:Piperpanel,BlackInstruments,CessnaPanelandTwinPanel.
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I'musingtheBlackInstrumentsbecauseyoucanmovetheinstrumentsaroundwithyourmouse(whilerightclicking
onagaugeandwhileholdingtherightclick,movingthemousearoundyoupositionthegaugewhereyouwantit).
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Youcanmoveeachgaugeseparatelyortheentiregaugesbyrightclickingonanemptyspotandmovingthemouse
around.Youcanalsoincreaseordecreasethesizeofonegaugeortheentiregaugesbyclickingonitandusing+
andonyourkeyboard.Soyoupositionthegaugesintherightplaces,andwhenyouexittheprogram,nexttimeit
startswiththearrangedgauges.ToaccesstheSettings,youpresESConyourkeyboardandselecttherightsettings
foryou.
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IreallylikethegaugesandIcanonlyrecommendthem.
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ArduinoLink2FS
First of a_ll i would like to thank Jim for his wonderful work on his
websiteandhisprogramLink2Fs.Itisagreatprogramwhichmakes
iteasytoconnectArduinotoFS.FormyCessnaIhavebeenusing
Link2fs and an Arduino Mega 2560 (Jim'spage) and here you can
downloadtheLink2FSv6directly(DownloadLink2FS6).Belowyou
candownloadthearduinocode(updated).
Cessna172WithEncodersFinal.ino
DownloadFile
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ThegyrodriftcommandisnotintheSimConnectInputstabsothere
is no code to add directly to the arduino code but there is another
waytodothat.OpenLink2FsandnavigatetoExpertstabthenclick
on the SimConnect Inputs (follow the picture). In the Y10 and Y11
writetheGyroDriftcommandsrespectively:
GYRO_DRIFT_INC
GYRO_DRIFT_DEC
HitRESETtoapplythechanges.
NowinthearduinocodewecanuseY100andY110forGyroDriftIncreasinganddecreasing.
}
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R5=(quad5.position())
if(R5!=Rold5){
(Rdif5=(R5Rold5))
if(Rdif5==1)Serial.println("Y100")//GyroDriftdown
if(Rdif5==1)Serial.println("Y110")//GyroDriftup
Rold5=R5
}
Note:Inthearduinocodeabovethesechangesarealreadymadesoyoujustneedtouploadthesketch.
Fornewbiesthesearethestepsyouneedtodo:
1.DownloadandinstallArduinosoftwarefromhere
2.DownloadquadraturelibraryhereandpastetheminArduiniolibraries
3.ConnectArduinotoPC
4.Openarduinocode(downloadabove)anduploadtothecard(don'tforgettoselecttherightcardandport)
5.Connecteverythinglikethepicturebelow
6.OpenFSXandloadaflight(chooseaCessna172)
7.OpenLink2fsandCARD1SerialComchoosetherightportandclickConnectorDisconnectCard1
Everythingshouldbeworking
*IforgottodrawthegroundfortheFuelCutOffswitch.
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FortheFuelcuttoffswitchiusedLink2FStoprogramtheswitch.FirstyouhavetoopenControlsinyouFSXand
assignakeytothe"EngineFuelValves(allopen/close)".Ihaveused""semicolonandclickOK.nowopenyour
Link2Fsandnavigateto"Key'sInputs"tab.IntheProgramingSection,clickontheENTERPROGRAMMINGMODE
button.Onceyouareinprogrammingmode,movetheswitchyouwanttouseforFuelCutOff(whichisconnectedto
arduinoonthecorrespondingpinsshowedinpictureabove).Aftermovingtheswitchyouwillseeanumberappear
neartheletterDwhichwilltellthepinnumberwheretheswitchisconnected.BelowtheletterD,ontheKeyInput
textbox,enter""(semicolon)withoutthequotesandclickSAVE"Key"codesandthat'sit.Youcannowcontrolthe
FuelCutOffwithadesiredswitch.
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Rudderpedals
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Tobecontinued...
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Pricelist
Priceuntilnow:
1.AlucobondIhadthe4mmalucobondsheetslayingaroundsoididn'tpayforthem.(a2mx1.5msheetisabout
83ithink)
2.Yoke50gotitonebay
3.Switches5
4.Screwshadthem
5.22inchscreengotitbrokenfromafriendandrepairedit(replacedtheinverter)5
6.Theframemadefrommetalscratchlayingaround.
7.Placardsprintedintransparentsheetsthatihadintheoffice.
8.Blackspray2.7
9.Knobs5
10.Mousewheelencoders6
Sountilnowabout75.
AbigadvantageistheCNC:)
Butsincethisisaworkinprogress,thepricewillbehigher.Asimentionedbefore,iwilltrytodoasmuchDIYasi
can,tokeepthepricelow.
AvideodemonstrationoftheCokpit:
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Ocorreu um erro.
Tente assistir o vdeo em www.youtube.com, ou ative o JavaScript caso ele
esteja desativado em seu navegador.
2015,CopyrightAlbEAGLE
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10/09/2016

In this page i will try to document my work on the Cessna 172

sides. Things to be done: Radio Stack, GPS, Parking brake, Fuel

I found the yoke on ebay kleinanzeigen in Austria for 45 Euro + 5

logo, and put double sided tape on the other

For the throttle/mixture i purchased 3 knobs on ebay like in the

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