My Personal Simulator Build

Version 2.0


A simulator is always an 'On-going project'


As it says above, a simulator rig is always an on-going project, if you decide to make one for yourself then you will constantly changing it, modifying it, and adding new things.

For years I have stuck with driving games, American Truck Simulator, European Truck Simulator, Fernbus and Tourist Bus coach driving simulators, Forza 4, and Grand Theft Auto 5, so my personal simulator was designed with these needs in mind, I designed a 'Car Style' cockpit around a real car seat.

My original Rig had to fit certain usage needs, it had to be both compact and yet hold everything I needed,  being as small as possible due to room size restrictions. The rig not only needed to accommodate use as a driving simulator with it's steering wheel and gearstick, it also had to double up as an office space, and somewhere to sit comfortably with easy access to my keyboard where I could spend many hours when writing my books. You can see the original build and the final result in the previous section by clicking here.


BUT THINGS HAVE CHANGED AGAIN!

Along with driving I have always been interested in aircraft and flying, yet the cost of building an aircraft simulator was way beyond the scope of my financial situation.  But now the prices are beginning to come down a little, and second hand controllers are more available in the marketplace, making the possibilty far more reachable.

The simulators have matured and improved greatly, they are no longer 'Arcade Games', and now compete with professional aircraft training simulators for their realism.

So I decided now was the time to get into it!


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Microsoft Flight Simulator 2020

The best flight simulator available to the public, Microsoft's flight Simulator has been around for many years, the current version was released in 2020, but a new release is expected in 2024.

MSFS 2020 as it is commonly known, covers both Commercial and Military style aircraft, both fixed wing and helicopters.

It comes with a set number of aircraft dependent on which version you buy, but there is a strong 'Mod' Community which has many others, sometimes free.
There simulator is compatible with most controllers, and there are endless additional components available such as Radios an navigation aids, and many add-on programs that add to the immersive realism.

So why do I need to make changes to my rig?

and what do I need now?

Simulation Gaming is not the only thing I use my computer for, therefore whatever I end up building needs to enable me to continue to operate it for ALL my other tasks.

I suffer a lot with severe back pain, which requires me to sit upright. I spend many hours creating and maintaining many websites, and I am also a published author and spend many hours on the keyboard writing. Therefore posture was a very important factor to consider, and balancing a keyboard across my knees was just not going to work.

The above still very much applies, I need the rig for all that I needed it for before, but now it has a whole new set of needs.

Driving a simulated vehicle, whether it a Car, Coach or Articulated Truck basically needs three things, a steering wheel, a gearstick, and a set of pedals. However when it comes to flying an aircraft these controllers are quite useless. The controls used for flying require a totally different style,  either a wheel type controller that has extra ranges of movement, or the use of a joystick, or both. The pedals used are also very different, they are not used as a throttle or clutch as this is normally done with levers, instead they are used for steering along with braking.
 
The type of aircraft flown too requires different controls, a Helicopter is again very different from an aeroplane

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The previous cockpit did well to meet my original needs, but just did not have the room for all these new controllers, so I realised that I would have to redesign it, somehow incorporate all the new controllers with all what I had before, and without having to totally dismantle one system so as to be able to use the other. This requires having the original normal driving wheel alongside a new push-pull style flight yoke, and the new throttle quadrant, but it had to be quickly moveable so that I could access both without changing my seating position. I also needed the ability to use a flight style joystick with either hand, meaning that instead of being mounted to one side as in a traditional modern aircraft, it needed to be fixed centrally.

New switch panels and instrument dials would be needed too, so new or additional Button-Boxes were needed.

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The original cockpit worked extremely well, and with everything built onto and into the unit, it saved a lot of room in an already limited space. It was built on large supermarket style castor wheels for easy movement, as I often needed access to the rear of the computers, plugs and the wiring, and of course for cleaning. But mounting 7 screens, one being a older 40" flat television, along with two computers, various switch panels, a printer, and surround sound system was making it weigh more and more. It was no longer easily moved by just one person, so a lighter redesign has become necessary. 

Due to the advancement in graphics, and the sheer beauty of the scenery in Microsoft's flight simulator, and in other regularly used top-end graphic games such as Red Dead Redemption 2, it was also time to update my monitors. It now needed 4K and not the 1080p of old, and it also needed bigger screens to add to the overall immersion. So an order was placed for three 43" 4K HDR televisions, these were the biggest screens that the corner of my living room could handle, as the larger the screen the further away from them you have to sit. 40" screens would have been suitable and perhaps even better, but it seems that the days of purchasing smaller 4K screen televisions are over, they are no longer sold in the shops, and now start at 43" and go up to a 100+"

These large televisions if mounted as direct replacements, would make moving my cockpit totally impossible. So I needed to mount the televisions onto the wall. My walls are mainly plasterboard/Dry wall, and being weak direct wall-mounting was a little worrying. I also needed one of the screens to traverse across the corner, so instead I decided the two side screens would sit on strong shelves rather than drilling holes for heavy-duty brackets, and the central screen would also sit on a narrow shelf diagonally across the corner. The existing 22" monitors will be refitted using the original mountings so they hung below the shelves, leaving the dashboard area free for the tablet displays and for some of the buttonbox controls. Weight saving would come from removing the high overhead 40" television, and the heavy bass speaker and surround sound amplifier from the front of the unit.

So from here on I will be showing the new build and all the modifications it takes to make work.

The New Build

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Strip-Down

The first job was to strip away the old screens, mounts and supporting framework, rear printer shelf and side panel to access the old wiring.

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Bigger Displays

Building corner shelving for the new 43" screens, and moving the heavy surround sound Bass speaker into the corner, and fitting the 3 front speakers to shelves. The heavy amplifier, radio and Wi-Fi printer was moved to an adjoining Hi-Fi cabinet.

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Sliding Shelf

Mounting all the controllers onto a sliding top board which would enable quick transition for Driving/Flying.
A shelf was made at the front of the unit to store the extra pedal unit, making it easy to swap over.

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Expanding the screens

The original 22" monitors were suspended from the shelves, two of which are connected to the second computer which is used to run OBS, Discord, and Twitch control panels when streaming.

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A new full-width dash-panel was built from Plexiglass, and the three tablets reaffixed with Velcro.

The unit was also repainted black.

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The slightly shorter rig now fits snuggly upto the centre screen. The plastic roll-cage tubing allows for mounting of rear speakers and cameras. The mouse shelf reattached to the swing door, and secondary PC keyboard to side shelf on the left.

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The 747 Jumbo is a bit on the large size and not meant for Welshpool Airport

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Ready for flight

STILL THINGS TO DO

I still need to fit the indicator switch unit to the left of the steering wheel, and to build a detachable centre mounting for the joystick. The dash panel needs switches and digital radio/navigation displays to be fitted and the Plexiglass to be covered with the matching black speckled vinyl.

A secondary lever-style throttle quadrant has been converted into a helicopter 'Collective', this will be connected to an Arduino controller board along with the digital radio frequency counters and various switches yet to be fitted. The touch-screen tablets will use third-party software program called 'Air-Manager' and set to show the individual displays and various switches for the many different aircraft.

But then it's an on-going project, liable to be constantly modified and improved.

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Martin Smith

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Jessica Brown

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