Journey into insanity - aka: DIY Panel and Gauges

Journey into insanity - aka: DIY Panel and Gauges - Printable Version

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Journey into insanity - aka: DIY Panel and Gauges - sonjamichelle - 05-04-2023

I ALMOST have MSFS2020 fully installed and calibrated. Finished getting all my AI packages installed, got all my add-ons, and I'm settling in on the "array" of ancillary apps I want to run (littlenavmap, RealTraffic, datalink, AirManager, REX Weather Force, FSUIPC and a couple of other little apps).

I've been messing with some overclocking, trying to squeeze out a bit more performance on the beast pc. Right now I'm just trying to find the balance between OC and Temp. Just about dialed in. I may have to set up some auxiliary cooling. My workshop tends to get warm in the summers, the A/C unit is a bit small for the space.

Now to the "insanity" part. I've always wanted to add a physical panel and gauge set up. Over the the years and with MSFS2020 I've got used to the Garmin G1000 in the Cessna 172/182, the Diamonds and the Cirrus SR22.

So, with that in my mind I am working on a couple of G1000 panels, an "eight pack" panel and a couple of GNS430's. If the 430's work well I'll do a GNS530 upgrade. There ARE some ready made G1000's and GNS units from places like RealSim Gear, Simionic, Emuteq and FlightSim Builder. Of course the cost for those ready made units is a bit out of the budget right now. And at least one setup requires a couple of iPads. I don't like that idea.

On FlightSimMaker there are files to 3D print the Garmin bezels, knobs and buttons. You just have to add the screens, controller boards, knobs and buttons. With raspberry pi and arduino this has become much easier. Along with Air Manager I can pop out the graphical part of the panel and put it on the correct display with the corresponding hardware controls.

There is another app that displays the usual analog "steam" gauges to another display or onto one controlled by a pi. You can also use Air Manager to control switches and knobs attached to pi or arduino units to mimic the knobs, buttons and switches on the gauge.

I printed out the Sidekick Add On for the Honeycomb Bravo and sourced the electronics on Amazon. This has the parking brake, annunciator cutoff and start/cutoff levers for engine one and two. It mounts to the bottom of the Bravo and places those controls under the main levers.

I still have my Saitek Radio Panel. The AP panel's digit display died so I may build another AP panel with segmented LEDs and knobs. Still deciding since those controls are on the G1000 as well. My Saitek switch panel does not play nicely along side the Bravo and most of the controls are already on the Bravo. So off to the spare parts pile it went.

The Radio panel works well though. It will be mounted beside the Bravo and angled under an auxiliary monitor that displays LittleNavMap and my Windows taskbar. My 3 Saitek FIP panels will be mounted under the Radio Panel and will display things like my engine gauges.

Off to the right of those two panels will go the Garmin GNS430 units. And if they work well, I may upgrade to a GNS530. I already have a 3.5 inch screen and Arduino board on the way to start the first GN430.

Now besides the G1000 we HAVE to HAVE the "six pack"! Though with the particular LCD screens I chose, this will become an "eight pack". The usual six, Air Speed, Attitude, Altitude, Vertical Speed, Turn Coordinator and Heading. The extra two slots will most likely be a VOR or two or an ADF. But since it is based on an LCD, they can really be anything.

If all those work, I MAY source a tiny screen to replicate a wet compass to mount above the monitor. Hey, go big or go home, right. :mrgreen:

I'll take a few pictures of the process, but since Tom "locked down" the picture sizes I'll have to size them properly so they can be displayed here along with larger hi-res ones with a link. I'll add them as I go.

Just a quick preview of the "eight pack" panel that will be mounted under the G1000

[Image: eight-pack_sm.jpg]

HiRes version here

At moment I have to break it up into 4 pieces if I 3D print it. Or I can laser cut the base and 3D print each bezel. I'll play around with that and see what gives me the best results.

I'll will document the project on my Flight Sim page, "Sonja's Hangar" It will have links, parts lists, some videos, etc as I work my way down the rabbit hole.

Wish me luck and see y'all in the skies!

Re: Journey into insanity - aka: DIY Panel and Gauges - AS 2 Tom Little - 05-04-2023

Sonja, holy cow - "the skies the limit" is reality here! Can see how insanity could wiggle its way in Smile

. But the hard work is paying off and that is going to be (already sounds like it is!) a GREAT set up. I'd never want to leave the workshop haha

Amazing how technology has gotten us to this point - I mean wow basically 3D printing a cockpit - who would have thought years ago?!

Re: Journey into insanity - aka: DIY Panel and Gauges - sonjamichelle - 05-04-2023

Quote:Amazing how technology has gotten us to this point - I mean wow basically 3D printing a cockpit - who would have thought years ago?!

Add a Laser Engraver/Cutter and a CNC and you're in biz!

I have the Laser (Glowforge) but an itty bitty CNC that is pretty cheap and crappy. But, I plan to scavange the controller and some of the motors and build a DIY one. Lot's of designs and how to's out there from folks who've, done so.

Once I know out a CNC, I'm looking to do the same for a 3D printer. Make one that will fit MY needs.

AND as a bonus, through all of this I'm learning a LOT of new stuff.

Sh-t, if this stuff was around 30+ years ago, I would have been in hog heaven!

Re: Journey into insanity - aka: DIY Panel and Gauges - sonjamichelle - 05-04-2023

The first prototype of the "8 pack" panel.

[Image: 8-pack-left_sm.jpg]

Hi-Res Here

The board was designed in 3DS Max, loaded into TinkerCad to export as a Flattened SVG so it could be uploaded to the Glowforge Laser Cutter. It was cut from a small scrap of Basswood Plywood I had laying around.

The bevels were found on the 3D file site Thingiverse and printed out of Blue PETG on a Troinxy CRUX 1 printer. The prints aren't super high quality since this is just a prototype.

The bolts are just some simple machine bolts I had left over from a box of assorted bolts and nuts from Amazon.

Re: Journey into insanity - aka: DIY Panel and Gauges - AS 2 Tom Little - 05-04-2023

Incredible!

Re: Journey into insanity - aka: DIY Panel and Gauges - sonjamichelle - 05-04-2023

This is just a VERY quick and dirty test of the gauge sizing. The LCD is NOT the one that will be used.

I plan on using one of these two LCD screens

Waveshare 11.9inch Capacitive Touch Display

waveshare 8.8inch Side Monitor

[Image: Gauge_Size_Test_sm.jpg]

Hi-Res

And a crappy one handed video of the gauges in motion.

[youtube]OzOR1Lw3h-0[/youtube]

Of course things will look a LOT better with the proper display and the panel mounted properly against the screen. This was just a test and confirmation of values while editing the json file for gauge size and position. As you can see the Airspeed Indicator is cut off with this screen since it is only a 10 inch LCD.

Making progress!!!

Re: Journey into insanity - aka: DIY Panel and Gauges - sonjamichelle - 05-08-2023

This is the layout I'm currently going to go with.

[Image: 20230507192906-34673166-sm.jpg]

No final LCDs or other electronics have been installed. These are just the face plates and bezels to give me an idea of how much space I will need. Right now everything is just sticky-tacked to the two existing touch displays and the VolAir's yoke tray.

And we zoom out:

[Image: 20230507192907-6f6ce7de-sm.jpg]

The project photos can be followed here: https://gallery.designcreations.us/index.php?/category/145

I'll have a more in depth project page when I really get into the meat and 'taters of the project.

As it sits now:

The big 55" is the main flight sim monitor. I've found that FS2020 runs better with on monitor in full screen. Triple monitor performance isn't quite there yet, IMHO.

The portrait 27" to the right is where I put stuff like AI, Weather, data links for the instruments.

The 27" down to the right is where I place LittleNavMap, my flight plan and following map.

The 15" over to the left runs on a Linux based Intel NUC. Serves double duty at the moment controlling my 3D printers and will run Air Player 4 connected to Air Manager 4 to display other gauges and switches.

The Garmins will be run with a 10" touch LCD displayed my Air Manager and with hardware buttons controlled by an arduino. Project at https://fouldsy.github.io/piper-pa-28-flight-sim/g1000.html

Below the Garmins will be two 11"x4" LCDs that will display the "steam" gauges using Scott Vincent's Instrument Panel from github.

The old Samsung tablet runs Navigraph Charts.

Under the Honeycomb Bravo you can see the Sidekick addon printed in blue. This holds the parking brake, engine 1 and 2 start/cutoff levers and the annunciator cutoff button. Again these are controlled by an arduino.

Not pictured up above and a bit in front of the spare 'fridge is a 43" TV mounted to the ceiling. I use this for watch TV, and FlightRadar24 when it is connected to the PC.

Re: Journey into insanity - aka: DIY Panel and Gauges - sonjamichelle - 06-01-2023

Work on the cockpit continues.

I printed, installed and configured the Sidekick. It worked great! Added some nice realism to the experience.

A couple of shots of it in place.

[Image: Sidekick_1.jpg]

THOUGH, I've "evolved" from the Sidekick.

Went "hog-wild" on this one! :mrgreen:

[Image: Full_Console_Sonja_DA62.jpg]

It is "loosely" based on the DA62 cockpit. The "throttle" levers in the picture are the Fuel X-Feed/Cut-Off levers found in the DA62. The Bravo of course provides the actual throttle. Currently the Cut-Off levers are being controlled by the "mixture" levers on the Bravo until I print and assemble the lower part of the console.

Right now the top two sections are printed. The main Power Switch panel is assembled, programmed and works great!

The rocker switches were scavenged from the Saitek/Logitech panels. The AP Panel died, so it was sitting in the "trash pile". I was on Amazon looking for rocker switches and encoders when the idea came to me to just reuse what was in the Saiteks.

Once I pulled them apart I could see why so many folks have issues with them being seen, working and just crapping out. The main wiring was about as thin as fishing line. The common ground was more like a "drool line" of solder. Like they just spot soldered to the terminals, drug along to the next, spot soldered and so on. Kind of cheap if you ask me.

I cleaned up the switches and soldered in some nice heavier gauge jumper wires. Fortunately there was so much solder on the terminals I was just able to "reuse" what was there and connect my wires. Which was nice since I can't really solder to save my life! Some heat-shrink tubing around all my connections and we were in business.

The Power Panel uses an Arduino Nano programmed with MobiFLight to give me functions inside FS2020.

[Image: Eveloved_Panel_1.jpg]

On the Power Panel I have (from L to R):

Rockers: (from the old Saiteks)

Master Batteries (Master Elec)
Fuel Pumps (L and R)
Master Avionics
Pitot Heat

Toggles: (New from Amazon)

Left Alternator
LH Engine Master
RH Engine Master
Right Alternator

Push Buttons : (New from Amazon)

LH Engine Starter
RH Engine Starter

Above the starters are three LEDs (New from Amazon)

Left Toe Brake (Orange)
Parking Brake (Red)
Right Toe Brake (Orange)

The center red LED comes on when the parking brake is engaged. When I was testing the initial setup I saw that the parking brake LED was coming on as I used the toe brakes to taxi. That gave me the idea to use additional LEDs to light up when the toe brakes are applied. In FS2020 there are variables for the left and right brake positions. With a bit of PreCondition code the Parking Brake lights up when engaged and stays off while you taxi, but the orange toe brake LEDs light up as each toe brake is applied.

Kinda neat if ya ask me! :mrgreen:

The Gamin GTN750 is currently sitting off to the side drying. Once dry and assembled it will display the GTN750 with a pop-gauge" using JDs PMSGTN750 on Others Mod from FlightSim.to. This mod adds a GTN750 to most of the default Aircraft regardless of it having the panel by default.

I am using a 7 Inch IPS LCD Touch Screen Display powered by a micro USB and HDMI cable off the second Nvidia RTX3090.

I'll update the pictures once it is dry and assembled.

The rest of the console is yet to be printed. The Garmin GCU475 (or rather a look alike) was completely modeled from scratch using a reference photo found on Google. Everything will be 3D printed except the electronic components. FlightSimMaker has a turn-key version in development. I modeled my own from a reference photo to the one found on MyPilotStore. This panel will be a work in progress along with the main G1000 suite. a lot of printing, soldering and programming for those!

The cut-off levers will be 3D printed as well. You can see where I got the inspiration for the Power Panel. I MAY reuse the old Saitek USB Throttle Quadrant, but it too is kind of cheap and flimsy feeling. Not solid like the Bravo. If I print it myself I can really get the feel and response that I desire.

I almost forgot about the last minute Parking Brake addition. This was 3D printed and uses a toggle from one of the old sacrificial Saitek panels. Works like a charm!

Additional parts and items used in the build so far:

Arduino Nano V3.0 ATmega328P Microcontroller
ELEGOO 120pcs Multicolored Dupont Wire 40pin Male to Female, 40pin Male to Male, 40pin Female to Female Breadboard Jumper Ribbon Cables Kit
Yosoo Health Gear Light Emitting Diode Holder, 50pcs
EDGELEC 100pcs 220 ohm Resistors
Mobiflight to program the panel functions.
Air Manager v4 to display the Garmin instruments on secondary displays
MSFS PopOut Manager to "auto pop" the Garmins onto the desired screens.

Right now the G1000 instruments are just pop outs using overlays provided by Air Manger with touch and mouse function. These are displayed on a couple of ELECROW 10.1 Inch 1920X1080p IPS Touchscreen Monitors attached via a USB to HDMI adapter. I'll most likely upgrade to the 4 HDMI version as things get more "advanced".

Things are rocking right along. It will take time to print, procure parts, assemble and program the G1000 suite. I did begin to print some physical steam gauges, but the quality and smoothness just wasn't what I desired versus using an 8 inch 480 x 1920 LCD to display the gauges using Air Manger or Scott Vincent's Instrument Panel from github. Of course covering the LCD with printed bezels. I will most likely put the steam gauge LCD in place of the current Saitek COM panel. I'm thinking of building/modeling a nicer looking more compact COM panel using MobiFlight to provide functions. Even though I do have the Audio Panel from the G1000 suite, I like the idea of having a larger dedicated frequency readouts in addition to the G100. (My old eyes will like that much better!)

By placing the steam gauges above the Saitek FIPS, I can utilize the rotary knob on the Altimeter to adjust baro pressure. The other two FIPS will display RPM and Fuel for the Engines. This probably goes without saying, I'll eventually end up ditching the FIPS and building some nice 4" square LCDs with much better resolution and capabilities. Besides, the FIPs are always losing connection between reboots. I usually have to reach around and unplug one or more so SPAD.next will recognize them. A real pain in the keister. A usb hub with individual power switches helps with having to reach around back, now I just reach up and toggle the power for the FIPS and restart SPAD.

I purchased a few FIP gauges from the FIP Gauges site.. They have a nice selection of good quality gauges for about 5 to 7 Euros a piece. The RPM, Altimeterand VSIgauges are quite nice. There is quite a nice selectionto choose from. Buuuut, I can see the money flying from wallet now. One reason why I'd like to replace the FIPs with regular LCD panels.

I will continue to post updates here and on my Sim site (https://www.sonjas-hangar.us). On that site I will go into more detail of the builds, software and programming. I'll add some videos and nice hi-res photos too. (Psssst: Tom, why is the forum width locked??? You can only post 600 pixel wide photos!) Hehe, granted, that restrictions does make the forum flow better without oversized photos. But phpbb should handle the sizing automatically. Been a while since I've installed/configed phpbb though.

May your landings equal your take offs and keep your stick on the ice!

Re: Journey into insanity - aka: DIY Panel and Gauges - AS 2 Tom Little - 06-02-2023

Sonja the complexity is making my head spin LOL. Don't know how you manage this but the results once complete will be amazing to say the least! (Already very impressive!) And LED toe brake lights? WOW. :o

I do need to check on the photo width, had trouble with it before so got it to this point where at least is does keep everything in line. Unfortunately the resize was not working.

Re: Journey into insanity - aka: DIY Panel and Gauges - sonjamichelle - 06-02-2023

AS 2 Tom Little Wrote:And LED toe brake lights? WOW. :o

I'm still fiddling with those. I have to dive into the Mobiflight docs to get the exact code parameters. I got it working once, but since the last reboot the config didn't save. I lost a few functions and I of course didn't write anything down, lol.

AS 2 Tom Little Wrote:I do need to check on the photo width, had trouble with it before so got it to this point where at least is does keep everything in line. Unfortunately the resize was not working.

phpBB should have a setting for fixed width or "fluid" width. The exact place in the settings is beyond my memory. I THINK under general board settings. Might even be under themes, it's been a while. phpBB is one of those always moving targets. When you think you have it figured out, they make major changes.