Learjet 45 Simulator Project

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.

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

…took longer than expected, but the Bondo finally cured, and I was able to fill the shell wall voids with foam. It was more than a little surprising that it took so many cans to get it done- 12 in all. The clerks at the local hardware store where I was buying all this spray foam were, not surprisingly,  giving me the twenty questions routine. I’ve learned that telling the truth in these situations is not always the best policy.

It needs to stabilize for a few days before I can start trimming and sanding it down.

Learjet 45 Simulator Cockpit Shell with Foam

I decided to take a break from the interior for now. I’m just getting over a nasty virus and I need something to do where I don’t have to think too hard about it.

I’m attaching cardboard to the frame voids so the spray foam doesn’t stick to it. The foam sticks to the panels installed on the inside and they are removable.

I feel like I’m back in art class playing with toothpicks and glue.

Learjet 45 Simulator, Shell

Well, I’ve managed to fit my existing main instrument panel (MIP) skeleton in the shell. It’s good that I’m making progress, but bad that I won’t be able to fly for some time, since everything is torn apart. I had a flyable MIP outside the shell until now.

Now, I need to verify that my measurements are good and modify/create attach points and support pieces. I also need to modify the current glareshield structure. I’ve got new dimensional info and it’s not quite correct as it is.

Here I have both pedal floors in for a test fit. Just for fun, I decided to put the pedestal in too. It fits in-between like a glove! The pedestal sits up from the floor a bit higher in its final configuration, so I’ll eventually have to add a riser on the bottom. Considering I built it from plans I got elsewhere and months before I got the shell, it is a good sign that the dimensions of the shell are spot on.

Since I got version one of the pedal floors in my kit, I had to make some modifications before the install. Here you can see the starboard pedal floor in place for a test fit. The yoke columns will sit in the spot just aft of the pedal floors where the plywood base can still be seen. I will be cutting out the yoke column floor pieces next. These pieces fit between the pedal floors and the raised floor in the aft of the ‘pit.