Learjet 45 Simulator Project

My motivation for working on the ‘pit has been lacking lately-Not that I’ve been couch surfing or anything. I finally decided to upgrade my main development computer to a MacBook Pro. The portability will be really nice for those rainy weekends up at the lodge. It’s a fast Intel i7, so I can run all of my graphic production software and also have a virtual Windows session open for the FSX scenery design work and testing I’m doing. I’ve spent most of my free time in the last two weeks updating and transfering programs and files.

I’m planning on getting back to work on the sim in a week or two…

The shaping is nearly complete. I’m finally cutting around the edges so the panels will come loose again. The pattern on the panels gives the shell a different look. It reminds me of something that happened a long time ago in a galaxy far far away…

Learjet 45 Simulator Shell

I’m making great progress with the final shaping. Unfortunately, the foam putty I’m using is hard to get locally and in limited supply online too. I have to order it and wait for the next batch to arrive in order to progress further. I’m also being my usual perfectionist self, so that doesn’t help either.

It’s looking good though and there are only a few rough spots I need to clean up on the sides and the top, so sealing and painting will happen soon. I wasn’t as careful with applying the putty, and it got in the spaces that it shouldn’t have, so I’ll need to carve around the edges to get the panels to pop out like they’re supposed to. I’m not worried about that at all. It’s just one more thing on my list.

Learjet 45 Simulator Shell Side View Close-up

Learjet 45 Simulator Shell Front View

Um, yea. This sanding bit is taking much longer than I expected. Big surprise huh?

If I do this right, I shouldn’t have too much touch-up work after this sanding pass.

Learjet 45 Simulator Cockpit Shell Port Side Foam Putty Skim Coat

Well, the port side final shaping is under way. I’m using adjustable flexible sanders from AFS that are typically used on cars, but they work great on any curved surface.

Learjet 45 Simulator Cockpit Shell Final Shaping

Learjet 45 Simulator Cockpit Shell Shaping Close-up

AFS Adjustable Flexible Sanders

I’ve been battling bronchitis, so the last few weeks haven’t been very productive. Sanding tends to be bad for already irritated lungs. I’m ready now, with respirator in hand, to start the final sanding and shaping of the foam on the outside of the shell. After that, a coat of hardener and some green paint and then it’s on to the work I’ve been really wanting to do on the interior. Expect more activity here in the coming weeks.

Hey all, just a quick update to let everyone know I’m doing well. I have the sim temporarily set up with a DLP projector and controls, mainly so the family could fly it over the holidays. I’ve been flying it too, and am hesitant to tear into it, ’cause even in this state it’s lots of fun. However, I will be resuming the shell work as soon as I’ve worked off the pounds I gained drinking all that egg nog.

The rough shaping and sanding is done. Final sanding requires a guide coat, so I found some old acrylic paint I had sitting around and used that. What, you thought I wanted a purple plane? Only if I was Prince or a rabid Vikings fan.

Learjet 45 Simulator Shell with Sanding Guide Coat Applied

Just a quick update on my progress:

Phase 1: Rough trimming -Complete
Phase 2: Rough shaping -In progress
Phase 3: Foam putty (Fill in bubbles and other voids) -In progress
Phase 4: Final shaping (Various automotive block sanders) -Not started
Phase 5: Foam hardener -Not started
Phase 6: Paint -Not started

Learjet 45 Shell Foam Shaping Progress