Learjet 45 Simulator Project » Project Progress

Where Does the Time Go?

Captain — Sun, 11 Dec 2011 01:43:25 +0000

Well, My mini shell finally arrived. I had to thicken the inside for added strength. Here you can see I’ve got it masked and am adding layers of paint for final shaping. This has become quite the mini project in itself. At least this feels like I’m still building.

It’s gonna look great on top of my mini motion platform.

Mini Learjet 45 Shell for Mini Motion Platform

More 3D Modeling

Captain — Tue, 11 Oct 2011 00:03:43 +0000

Hi all! I apologize. It has been too long. Life has been pretty busy lately and I’m on the cusp of an exciting new adventure.

That said, progress is still being made on the miniature 3D model of the Learjet 45 for the test motion platform. I’ll be splitting off the motion control software to a separate site on nine point eight one, but I’ll also link to it from here, so you won’t miss a thing. Progress on the full-size shell has stopped for now, but once the weather cools off, I’ll be back at it.

Miniature Learjet 45 3D Model for 3D Printing

Micro Servos (Fit for a Tiny Elvis)

Captain — Thu, 23 Jun 2011 23:47:40 +0000

Found some micro servos that can be used for the yaw coordinator. The technical drawing is full scale. I’m still not sure how I want to build it yet, but I have a few ideas floating around in my head. The experiments continue…

Micro Servo and Yaw Coordinator Technical Drawing

Yaw Coordinator

Captain — Sun, 12 Jun 2011 23:58:14 +0000

I’ve got my software working reasonably well, so I decided to build a quick and dirty mock up of a yaw coordinator and test it out. The ball shakes a little too much, because the connection wire to the servo is a little too thin. The final design will be more complex, due to the slight curve of the glass tube the ball sits in, but this gives me something to play around with while I’m finishing up the software interface. Sorry for the low-quality video.

I need to get back to finishing the shell exterior. One of these days I’ll get back to it.

Where do they sell Learjet Windscreen Templates?

Captain — Fri, 26 Nov 2010 19:13:05 +0000

So I can’t find any door skins – thin plywood usually used to cover hollow-core doors – to use as windscreen templates, so I had to order them from California. I initially thought about using 1/8-inch MDF, but the edges don’t hold up for what I’m going to do with them. The templates will be installed while I complete the fiberglass covering, so I can get a good fit when I install the final Lexan windscreens.

Learjet 45 Simulator Cockpit Shell Painted

Hey! Who put a Learjet in my Basement?

Captain — Tue, 16 Nov 2010 03:31:04 +0000

The foam has hardened, and just one more coat of paint up top before the real fun begins.

Learjet 45 Simulator Cockpit Shell

Paverglass Update (Paverpol+Fiberglass)

Captain — Mon, 01 Nov 2010 02:55:40 +0000

Happy All Hallow’s Eve!

Well, the “Paverglass” is hardening nicely. It’s rather pricey, but much easier to work with and way better for my lungs and liver than resins. The test piece is a little lumpy and uneven due to my stress tests, but it is as strong as I need it. BTW-I’m using four layers of fiberglass matting.

I’m touching-up the shell roof for hardening and painting. Those compound curves are a little tricky. When that is complete I’ll be splitting the shell in half to make it easier to work with the final “Paverglass” covering.

Learjet 45 Simulator Paverglass (Paverpol+Fiberglass)

Painting the Shell

Captain — Sun, 24 Oct 2010 03:36:11 +0000

The port and starboard side foam has been hardened and I’ve applied a fresh coat of paint. It’s a slightly different color than the Apple Green I’ve been using, but the final coat will be Apple Green. If you were wondering why I’m using green, it’s very close to the special corrosion-resistant paint used on the frame parts of real airplanes.

My experiment with fiberglass is continuing. Apparently it can take up to two weeks for the Paverpol to harden completely. Right now the test piece is still a little flexible. Either the Paverpol isn’t completely cured yet, or I need to add a few more layers of fiberglass. We’ll see.

Learjet 45 Flight Simulator Cockpit Shell Painting Progress

Fiberglass Cloth and Paverpol

Captain — Thu, 21 Oct 2010 01:55:21 +0000

While building this thing I’ve been trying to figure out what to use as a final shell covering. Others have used the traditional fiberglass method, but they are building something more permanent. If you didn’t know, using toxic resin and hardener indoors is a really bad idea. Fortunately, I think I have stumbled onto a fabulous solution.

Paverpol, the fabric hardener I’m using to harden the shell foam can also be used with fiberglass. It’s completely non-toxic. That’s right, NON-TOXIC! It has traditionally been used by artists in the creation of fabric sculptures. This stuff looks and smells like white glue and dries rock hard. Testing is under way, but so far it appears to be a good alternative.

Learjet 45 Simulator Cockpit Shell Fiberglass and Paverpol

Unfriendly Skies

Captain — Tue, 28 Sep 2010 04:35:27 +0000

Sorry for the lack of updates. I’m finishing up a few house projects before old man winter arrives and also cutting my teeth on some new development software. Work on the pit is continuing, however. I’ve hardened the foam on the port side and have started the process on the starboard side. The light at the end of the tunnel is visible, at least for the shell exterior.

I’ve been flying low and slow in a Beaver float plane for a change of pace. My last flight was quite the adventure as you can see below. Apparently I wandered into restricted airspace or something…

Shell pictures soon!