Above you see an image of what we call the Glare. It includes the most important interface module for the AutoPilot - the MCP (Mode Control Panel) together with two NAV-radios. This unit is centrally mounted and easy accessible for both pilots.
On the top (not seen here) you have the Glare Shield which covers the area between glare panels and cockpit windows. At each end (Glare Wings) you have a light control panel for each pilot controlling misc. light sources in the cockpit. I decided to start the whole build with this central unit - 2 times VOR and MCP. Rest of the Glare parts and window frames will have to wait until later in the project.

So how to proceed:
I need housing for these three instruments matching the real housing as close as possible. I also wanted to add necessary I/O - electronics covering the same instruments and those in surrounding area.

HOUSING

Many hours in Corel Draw and photo research gives a rewarding result in the end. By doing the drawing, force you through a lot of planning and verification. In general I utilize the Layer functionality heavily where all parts involved are stacked and you see any mismatch at once. So in the end when you start the hard work - and in my case as you know on the CNC - everything matches 100%. It's a great feeling to discover that the theory and final piece match.
To the right you see the box in its early stage. Material used is 6mm MDF. It's really great material to use for this kind of demand. All the parts are slotted as in the drawing and glued together in the end. I made the holes for most of the connectors (still missing a few for e.g. external power wiring). In the unit I've put: 1 x USB expansion 1 X Master Card 3 x Display II A few more PCB's (for lights control) and a Power Supply will be put into this unit at a later stage. Also the I/O wires/electronics for the two Glare Wings panels and Master/Caution switches ends up here. To utilize the available input/output on the MasterCard, I will also route the wires from the two ISS (Instrument Source Select) panels on the MIP into this box. Underneath showing some more picture of a ready painted unit, panels and electronics installed. It's not a beautifully sight, but practical. As you see, I try to use ribbon cables where ever possible and that's a general rule all over in the cockpit.
Glare housing wiring diagram - Apr. 2010. Still not 100% complete while missing wiring for the Glare Wings (Light controlling electronics), Master/Caution and Power Unit. Click on the image and you get a pdf-document (possible to zoom)

MCP

This has so far been the most demanding part of the project. As said some other place on the site - if I ever managed to make this unit, everything else is piece of cake. This is almost true. There are of course other parts which are difficult to make, but on this module all my panel techniques would be "tested". The CNC would finally show its capabilities.
I will go through the build process for the MCP in some details and again the drawings (both Corel and Diptrace)
are the most vital part together with the construction principle. The process goes like this and it's the same for all panels.

• Find all the information about the panel
  • Pictures
  • Measurements
  • Number and type of 7-segments display
  • Number and type of switches, encoders, rotaries etc
  • Back light and Button light - e.g. colors, where to place and numbers.
  • Labels

Then the drawing can begin. Using layers heavily - 9 in total.
Making all placement of components, cutouts, screws etc - exports the necessary information to
Diptrace for PCB layout. I've imported back into Corel the PCB layout just for verification.

Before doing the PCB layout you need to develop the electronic schematic or wiring diagram.
I did that actually in parallel with the panel drawing. From the Download section: Part1 and Part2.
(I had to split in two due to size). I'm also using two PCB board - again due to size.
Then I made some simple jumper-interconnect between the two as seen in some of the images below.
And as usual - pictures tell much more than words.


Concerning the backlight there are a few ways to implement. I have chosen a very simple method - just stretch the LED's up from the PCB through the backplate. Next panels may be done differently.

Your eventually design may be different, but at least for the B767, mine is working great.
In general the design and layout of course depends of many aspects. What kind of 7-segments, switches,
encoders etc you are using. The clue is to add all those specific components to your PCB layout component
library and nearly everything falls into place. Here is my PCB layout:



Those two small PCB to the right is for Bank/Heading selector - combining an Encoder and a 12 position Rotary. I chose to make that combination as one unit and with its own connection to Master - in other words it's not part of the main PCB.

	When all drawings are ready it doesn't matter which part you finalize first. I did the PCB first because I was eager to test the functionality. The panel itself is straight forward starting from the back with a 3mm acrylic sheet with necessary cutout for components.
	Then mounting the PCB at the back. And if your drawing is "correct" everything slides straight in and you use the nuts on switches and encoders/rotaries to fasten everything though I have added a spacer for each front screw to keep everything in place in the end.
	Korry production - again cut as in the drawings. Then painted and labeled. Look in video section for clip from production - both concerning button and knobs.
	Now the Front panel - the most "visible" part. The same material used as for the back panel, but now 6mm PMMA. Milled from both sides. Look in the Video section for a clip from the process. Not any special tricks - again just follow your drawings. The only issue you need to get correct is the depth of milling. As you see it varies depended on what feature. In the back light area I mill to a depth of 4,5mm.
	The last operation is painting and engraving. Not 100% satisfied, but good enough. I may try a different approach further down the line. The problem is the size of the panel. I may need to mill limited to smaller areas and more shallow. The painting could also be better and the same goes here - the technique getting better for every panel. Going to invest in an Airbrush!!!
	Left and right images shows how the Korry switches operate. The button is held in place by a spring on top of the Tactile switch. The cutout in the back panel is functioning as switch housing and guide.

VOR

The two NAV radios follow the same construction principle as the MCP. Look here for more details

In general - please ask if something unclear. I have a lot more information - I just have to keep the writing to a minimum.

Per-Erik / May 12, 2010 15:16