767-300 Cockpit

The image above show the current (spring 2010) version of my MIP Corel drawing.
The building process is from Left to Right and I've broken up the MIP into four main modules - MIP 1-4. (CP left and right, FO left and right). Bezels around ADI/HSI and EICAS are built separate. The reason for this break-up is mainly due to production and modularity.
The principle for the MIP is simple. Three LCD's installed where needed - two 22" and one 19". These monitors are placed as close as possible to the front panels which implies some tricky switch construction. The CNC unit is the answer and makes it possible to machine some really nice and small mechanical parts.
The material used for the panels is mostly PMMA-CL - cast white polymer.

MIP-1

	This is the easiest of all MIP sections - two instruments and ISS (Instrument Source Select panel). I don't count in the Taxi speed gauge - it's just a cool add on. The drawing show every cutout/slotting which needs to be done in the 6mm PMMA. Some cut in front and some at the back. We have also the first tricky switches -. ADF left and right selector. In 6mm you don't have too much space. I'm using two micro switches from a PC mouse placed in a full cut slot. At one side of the switch (facing the small switch knob) I made a pocket formed as in the drawing. It's made as a rotary and the pin is a piece of PVC made on my CNC index-wheel. The drawing shows also a side view where you can see the steel ball and spring. I don't have a good photo of the working piece and I don't want to "open" it again - afraid of springs and steel balls all over the place :-) Both switches are covered by the RDMI bezel.
	To the left you see the front just before the final pocket run. The backside (right picture) you see the slotting for wires to/from the micro switches.
	More or less finished RDMI with 1mm plexi installed. Knobs are not too nice, but OK as prototypes.
	Even more complete MIP1 - now with foot-rest, a ready ISS panel which I'll cover next and ADI/HSI bezels. BTW - All ordinary bezels and instrument panels with a few exceptions are made of the same material as the MIP; PMMA-CL - 6mm and milled as in the drawings.

Instrument Source Select (ISS) panel

	Instrument Source Select (ISS) Panel is quite simple. Four 1" Korry switchesandone 3-positions Rotary (45 degrees detent and actually a 8-pos, but blocked for just 3). I’ve milled at the backside to make room forbacklight. Painted and engraved as normal. Concerning the Korry switches you can take a look at a tutorial I've made. All the misc. knobs on the MIP-1 panel are milled out of MDF as you certainly can observe. The finish could have been a lot better. I may replace all further down the road when I'llgoing to mill Acrylic or doing moulding from a high quality master. All the knobs you've seen so far are all prototypes and "first cut".

The wiring for ISS electronics is simple - collect all signals in one connector. Also routed the RDMI switches to this panel. The signal cable (25 wires round cable) is routed to and terminated in the MCP housing. I have made the 1" Korry as a standard component in my layout PCB program so it's easy to add new switches and all do contain the same components which are one switch-transistor, three resistors and two LED's. The switch is powered by the Backlight power source, so the intensity of the LED's is following the Backlight intensity which is the same as in the real aircraft. In the schematic you'll see two LED's for each Korry. In this panel it's just one LED (upper) installed as the lower part of ALTN-Korry are not active - just showing a white line. Installed 8 Backlight LED's and I hope it's sufficient. I can add more if necessary. ISS PCB layout follows the ISS panel in Corel drawing of MIP. Placement of Korry, rotary, LED and fastener are all 1:1 with the main drawing. All cutout matches - the same with the end result.

ADI / HSI bezel

	ADI/HSI bezel is like a prototype using 12 mm MDF. I've milled from both sides to able to make all details and using one piece of MDF except the cover plate above ADI which is milled separate and glued to the base in the end. No specials - again just do as in the drawing. To the right you see the HPGL file (export from Corel Draw) with a separate color for each layer. Below is the drawing after imported into SheetCam where all the path and tooling setup is done. In the end made a couple of 1mm Plexi "windows". ADI and HSI is the same for CP side and FO side - just mirrored.

Per-Erik / June 18, 2011 10:13