Welcome to A320Sim.com
The diary of a simulator builder
The Concept
This site documents the progress and the thinking behind my A320 Flight Simulator. I will add to it as the construction progresses in the form of a blog.
I have always been interested in simulation and in my professional career I saw (and sometimes flew) many simulators; these were mainly military full simulators and part task trainers, also a couple of combat flight simulator domes. I never had any contact with heavy metal types although I would have liked to have done so. It is possible to buy time on commercial simulators but these experiences in my view are too brief and too expensive.
Having been flying on Vatsim for some time and made contact with other simulator builders I felt that building a full cockpit was one of those things in life that has to be done.
The Builder
Scope of Simulator
I toyed with the idea of a desktop simulator using Go-Flight panels or similar home made devices. This developed in the thought process to a more realistic cockpit appearance but I decided that the only thing that would satisfy me would be a full size cockpit. I briefly thought about a half cockpit and if space were a problem it would be the way to go. I had, however a number of options on space and felt that a dual seat full replica would be better, I can them teach some of my six grandchildren to fly in a two man crew.
I decided to initially produce the main instrument panels, the pedestal and the side panels and get the simulator flying using a monitor for outside display, this would sit in a spare room in the house. I would add the overhead, windscreens and a projector as "phase 2" and move the simulator into the house loft which is an ideal place for the final configuration.
Barry Kensett is an aircraft designer by trade having spent fifty years in the industry but now long retired.
He started his career on the de Havilland Comet and later worked on many aircraft including Trident, Airbus, Buccaneer, Phantom, Harrier, Hawk, Phantom, AV-8B, and latterly was Project Director.
Flown many aircraft but never able to get a licence due to eyesight problems.No longer interested in high-G flying but still flies light aircraft occasionally.
Always interested in simulation and still keeps in touch with the industry.
Choice of Aircraft
The Vision
To a certain extent my choice of aircraft was prompted by career experience but also the availabilty of parts as I do not intend to build everything myself. As a very long time retired old gentleman I do not embark on long projects for the same reason that when I get visits from financial advisors telling me I should "take a long term view" I have to point out that I haven't got one.
I quite liked the idea of the HS 125 as I worked at the De Havilland factory when it was being designed and later was my favourite executive jet but there is not much made for the aircraft. I am also a great fan of Concorde, a technical marvel the like of which we will never see again, but the thought of all those analogue gauges is daunting as is the thought that it could be flown single handed.
Eventually I had to be realistic about what I could build and have flying within one year; that brought me down to the Boeing 737 or the Airbus A 320. Hardware and software for both types is readily available. I chose the A320 for a number of reasons, the emotional one is that I worked on the first Airbus design (the A300) in 1967 and have been involved in some way with most variants since. The aircraft is technically far more advanced than the 737 but for a simulator this could be a disadvantage as the complexity and antiquity of the 737 cockpit, whilst out of date in the real aircraft world provides a certain vintage charm for a home simulator.
The final choice took into account the relative simplicity of the build which will enable me to get flying earlier and cheaper than the 737. The sidestick is far easier to replicate than than the interconnected yoke and column of the 737. The Airbus power lever assembly is far easier and cheaper to produce. The TFT screens are more straightforward. Whilst I chose the A 320 I have no problem understanding why many pilots choose the 737.
Getting Started
Having selected the rough scope of the project I still had not made up my mind to actually do it; the simulator would take all my project time for a while and I had to be prepared to take time off of other projects. In December 2006 I decided for fun to take on a mini-project and build an A 320 throttle (sorry, power lever) box; I had seen the standard and price of those on the market and felt that I could make a much more robust, aircraft like unit for less than £20. It took about four weeks of part time work. The detents and reverse thrust mechanisms work exectly as the full size aircraft, I have put in provision to motor the trim wheels but not fitted the mechanism yet.
In January I decide to build the full simulator. There are a few suppliers but I decided to go with Flight Deck Solutions for the bulk of my bought parts but it took some time to get the information for a mega order of parts.The IBL panels had only recently appeared and the website was not up-to-date with these. It was also not clear whether the hardware listed was still relevant to the new panels. Eventually I managed to get a coherent parts list and price and placed an order in the first week in February.
In the meantime I was looking at FDS Forum posts and noted that one of the contributors had an e-mail domain which could only be local. From this I found a guy building and A 320 sim only a few miles down the road. We now have two A 320 pilots on tap giving us information on e-mails and would you believe that one of them has just embarked on his own A 320 sim!
Building the Power Lever Assembly
A320 Power Lever Assembly
More pictures here
Waiting for Parts
While waiting for parts I scoured the net for pictures and tutorials; also went through the various forums to get up the learning curve. I managed to produce some sketches of the way I intended to build the sim but it was obvious that very little could be done until I had the MIP panels in my hands.
I decided to attack the main panels, the sidestick boxes and the pedestal. The overhead would follow as an add-on project later. I could set up some temporary switches on the pedestal to cover the overheads systems necessary to fly.
I propose to do the systems development using a monitor for outside views but to get a projector eventually.
I initially assumed that I would use Project Magenta software but they increased their prices around the turn of the year. I thought that this was now poor value for money and with the prospect of AST coming good in the timescale I needed and did not jump in and buy PM before the prices went up. AST is more specific to Airbus than Project Magenta but there is the risk of more bugs in the more recently developed software. The AST people were rather cagey on update policy which needs watching.
My first delivery of parts arrived from FDS on 21st April 2007 and things could start in earnest
When a parcel arrives from FDS it's like Christmas!
Choice of Monitors
I was initially told that I would need 19" displays for the PFD/ND but these are too high meaning that the monitor not only projects up into the glare which is OK but not high enough to lose all of the excess. The monitor then projects down below the MIP which is why some cockpit pictures show and extended lower edge. I felt that it should be possible to use a 17" widescreen monitor for the PFD/ND and once I had the panels I could measure and confirm this. This solution avoids having screens that project below the MIP and the they are cheaper than 19". I bought two Hanns-G 17" widescreen monitors HW 173D from CCL (http://www.cclonline.com/) which have a viewable area of 361mm x 198mm. These are excellent value and performance for the task.
For the ECAM display I prefer to have the standby instruments functional even though they are "eye candy". To cover the ECAS screens a viewable area of 11.75" (300mm) wide by 13.75" (350mm) deep is required. This is just covered by a 19" monitor on edge; I got an LG screen from the local Argos store, I chose this as it has a very narrow bezel - things are a bit tight in this area! This subsequently proved not a good choice; the instruments are very clear from the pilot's seat but hardly readable from the first officer seat. With the screen on it's side I am trying to look from what would be the floor if it was mounted right way round. The screen does not have a good enough angle of view from this direction and eventually I will pay a little more and get a better one.
One problem with the 19" screen is that the "Terrain on ND" switch and light will not fit due to the screen behind; it may be possible to mount something on the front of the panel.
There is a risk that the 17" screens will become obselete. In the unlikely event of a monitor failure in say a couple of years time it may be difficult to get a replacement.I therefore bought another one for the "instructor" station which could always be used as a replacement for the ones in the panels. I am so pleased with the fit that I would not want to have to fit a 19" screen later.
I am not so concerned about obsolescence for the EWD/SD screen as I am sure 19" screens will be available for many years.
Main Instrument Panel Framework
It was important for me to be able to move the sim around, to this end I made the main frame structure in three separate units bolted together. The primary structure is all screwed as I felt that even with the best forethought and design it was likely that things would need to be modified as the build progressed. In fact this has not materialised but I am still reluctant to glue.
I have left space in the back of the centre module to take two computers. Large cutouts in the top of the side panels are to allow for wiring to be dropped in.
I took a sample panel to the local paint mixers to have some matching paint made up.
I decided to use birch plywood for the main framework, I don't like working with chipboard and MDF. I initially bought three sheets of 9mm and one sheet of 6mm which stacked nicely on top of my trusty trailer.
FCU/EFIS
17th May the FCU/EFIS arrived from FDS so work will start on the glareshield soon
Wondered what these connections were for and had to e-mail FDS, the 4 pin plug is for firmware updates and the twisted pair is the 5 volt input for the backlighting.
It will be difficult to fit the upgrade plug with the wire there, I think a modification is needed to bring the wire out through another point.
That's better!
The Pedestal
The general effect is starting to appear, the throttle sits lower of course but a couple of notches neede to drop it down!
20th May 2007 the pedestal is starting to take shape
The box is 9mm birch ply with the top edge thickened to 15mm. The recess is for the chart pocket.
The rear box is bolted to the forward box.
The FMGC is too wide to fit on rails, I mounted it into a stirrup at the front end and the rear rests on the cut short rails.
The red outline is where the FMGC fits
The lighting plugs for the IBL panels will often foul the rails and cutouts are needed,
When the hardware is fitted to the panels I would guess that more cutouts will be needed
The Glareshield
First trial fit of the FCU/EFIS
Basic structure complete
Building the ACP panel
Details click here
Main challenge here is to get the overhang stiff and not flopping about.
There has to be humour in this sort of project, one of my "friends" sent this picture of my wife disturbing the outside views !
Things slowed down (as I knew they would) in June as we had nearly three weeks on holiday. Gardening then had priority over the simulator but quite a lot of painting has been done.
Also the sim has been moved from the woodworking bench to the assembly area in another garage. Hopefully I can start to assemble the panels back into the structure and make some positive steps to get flying
. 
ECAM Complete
Building the ECAM Panel
Work has started on the ECAM panel which should progress rather quicker than the ACP.
The ECAM selects the various systems to be displayed on the lower ECAM display.
More details here.
Coming together in the assembly shop - July 2007
Building the Glare Panels
More pictures here
A temporary monitor shelf has been fitted over the glareshield to assist in software setup and also to provide some semblence of outside views to get the sim flying until the projector(s) and screens are brought in.
Three computers have already been assigned to the project so the push is now on to get into the air. The project took a step back when one of the PC's wouldn't load Windows. It's been troublesome before which is why it was replaced as my main desktop. I have ordered some more bits and a couple of cases. Like most computer literates I have loads of bits lying about so I don't have to spend much to get an extra couple of computers. The sim of course only needs one good PC for Flight Sim and the graphics. Out-of-date ones are fine for the others.. I reckon I need one pC for each display (I know some people use multiple outputs or cards) so on that basis I need five at least, probably six to provide an instructor station for setting up.
I am using RealVNC to talk to all of the PC's from one disply, mouse and keyboard.
General view August 2007
I like spaghetti but not with my wiring, this will have to be tidied up!
Doesn't look to have advanced much in the last couple of weeks, this is because the time has been spent sorting out the computers.
The AST software suite arrived and the server has been set up on the main (FS9) computer and the pilots display software on another. When I fired it up it didn't work! Was I surprised - well not really that's what it's about!
I then tried to fire up the Plug and Play FCU, well I plugged but I couldn't play because apparently I need some more software to use it with AST.
I then tried out my throttle and this was much more successful. I am using Flight Deck Technology interface cards for the pedestal inputs as there are a number of rotaries and FDS don't have a suitable board, the joystick card is not really big enough. I have an FDS SYS3 card for the MIP inputs and the outputs for MIP and Pedestal. You can see the FDT Master module and input module in the picture on the left.
I found the throttle easy to set up and it exceeded my wildest expectations. The resolution was fine with good control and the reverse thrust worked as it should. I obviously got the gearing about right but I had about 10% N1 mismatch between the two engines meaning one lever was ahead of the other for matching N1. I think I can sort that in the software but I might just rotate one pot a bit which is whre the glitch stems from.
I think I will make a temporary switch and button panel in one of the vacant pedestal bays to give me limited overhead functions (APU etc) and also for gear, flaps and airbrake until I get the hardware built. I have found that a 1964 Rover 110 overdrive switch is just like a gear switch but without the pull gate. That will do for a bit.
The joystick I have been using for years is a CH Pro which is very good but it is a gameport device. I thought I would need two USB joysticks which can be used "as is" now and be modified and buried later. I got two Logitech Attack 3 sticks on eBay (Click here), I gave £1 for one but was pushed to £4 for the second. They are like new with 11 buttons and have a fairly stiff spring so may not need modification when I put the Airbus handle on and drop it flush with the sidebox top.
Lit up AST for the first time
Well it's not all there, I can't get the windows in the right place and the ND is egg shaped. On the plus side it is in sync with FS9 so I must have got something right!
This picture of a 1910 simulator stimulates some thoughts on a possible motion system!
Spent a lot of time over the last couple of weekls optimising the computer suite. I have five so far to cover each display but I want one extra to control everything without having to use a sim display. To avoid having to use five keyboards and rodents I am using VNC.
She flies !!
Ah I am getting the hang of this AST. getting the monitor resolution set up right makes the circles round. AST config software works very well in positioning and scaling the windows. The standby instruments are set up in a different way to all the rest but there is a step-by-step manual.
After some experimenting I found that it is possible to run both the pilots and FO displays from one PC using a graphics card with two outputs. The AST software works fine with this arrangement, as can be seen above it is not a clone but a separately running program on each side. That has released one PC for me.
My next challenge is getting the FCU/EFIS running. I seem to be the first customer for the interface software so am needing a few e-mails to the developers but I am sure it will come good soon.
Got the software working and the FCU lights have come up.
Not so much fun flying mine as it is three years behind Darren's but we are getting there. The displays are scrambled in this shot as I have been playing with resolutions while trying to get the FMGC screen running. I tried it on all the PC's currently in use on the sim and have a few issues to solve.
We had a couple of visitors to see both my Sim and Darren Sugden's (Suggy) who lives close by and whose A320 is much more advanced; in fact he uses words like "nearly finished". It really is a marvellous experience to fly Darren's sim, he has made an excellent job.
The two visitors are both intested in building sims for professional use and came to see the standard and quality of the FDS components mainly. One came up from London and one from Manchester. We had a good day with both Darren's sim and mine.
Darren flying his sim, a ready to taxi view, the panel lit up and a rather nice passenger's eye view.
All screens working!
I have got the seats and one can just be seen in this picture. I got a pair of new Recaro seats on ebay for £40. The trim pattern on the cushion is very similar to Airbus but they are in grey rather than blue in the Airbus. They are really comfortable and came complete with runners; I have mounted them on boxes to get the height right.
I know this website has been a bit quiet lately, it's not that I haven't been doing anything but it's difficult to take meaningful pictures when trying to sort out software. I had particular problems getting the FMCG and the MCDU working but it's going now and I just flew for the first time under some sort of FMGC control.
I'm still having a bit of a problem with the MCDU screen - details
I have now opened up on a new front; as the weather cools down I can get working in the loft where the sim will end up. I have a space 30 feet by 11 feet (yes that's big) so I am fitting a Velux window for ventilation and lining it out with plasterboard. Hopefully then I can get the projector(s) and screen installed and really start to experience the thrills!
The hangar is coming along nicely, A roof window has been fitted and the area is now being panelled, only a couple of days more work on that. Then a clean up, some better lighting and then the sim can be moved up here. It will be a superb space, the width and height are more than enough for the cockpit, the challenge will be getting the screen in place without the roof chopping the view down. I have plenty of length to use back projection, perhaps that is the way to go. The overhead panel will not then impede the projector(s).
First light up in new hangar
I have some modifications to do on the pedestal so the panels are not yet fitted. Similarly I have to paint the seat bases. It cries out now for a projector and screen, Father Christmas, are you listening?
RMP Panels
While having a break from the hangar construction I have started to look at making the radio panels. FDS are not offering any at the moment so I will have to make up my own. I have accumulated a few handy bits from various sources, I now have to stitch them all together.
I have made the switch mounting plates and have incorporated matrix board sections to mount the encoders and the digit displays.
For more information and pictures click here
Some general views December 2007 - 8 months into the project
Engine Start Panel
More details here
Major milestone !!
Tuesday 18th December first on-line flight. OK it was quite short, EGBB to EGCC, but ATC all the way on VATSIM. One snag was FMGC locked up but flight plan was still visible on the ND so not too much of a problem. I also neglected to put pitot heat on and lost speed and altitude information for a while. The aircraft carried on with the flight plan however until the heat was effective and the instruments came back.
One issue to resolve is the lack of thrust on take-off. Having set the throttles up in AST using Autolearn it tells me that I have 102% N1 available; however in TOGA I cannot get more than 90%. Checking with my friendly A320 pilot he says that I should see at least 100% at ISA (15deg C and 1013 mb). Not sure whether it is the aircraft model I am using (Project Airbus) or a software problem.
The second issue is the lack of response to rotation at Vr which typically would be between 120-140kts but I need 160kts.
Taking the two problems above I need long runways at the moment to take off!
Flying online itself dictates the priority of working now. Need to finish the radio panels to tune into ATC, currently I have to use Squawkbox. Also I am still using a keyboard for certain commands e.g. Flaps, Gear, Airbrakes. From a functioning point of view the panel lighting is way down the priorities other than a wish to see it all lit up.
Bulk wiring has now started, for more details about the interface cards see here
Also the first trials with a projector have commenced, this is a BenQ unit mounted upside down on the roof and is front projecting. This will get in the way of an overhead of course so may be further developed with a mirror and back projection later.
The lighting is now starting to come together. I am using a PC power supply and have put 5 volt and 12 volt ring mains all round the pedestal with breakout connectors and plugs to fit the backs of the IBL panels and the MCDU. I have also connected the 5 volts to the FCU/EFIS.
I have an issue to solve with the brightness of the MCDU. It is fine on the bench and checking the voltage in the ring main it is actually nearer 4.5 volts; this may be due to the load of the backlighting combined pulling the voltage down. As the backlighting is plenty bright enough I don't need to lift that to five volts; I would rather leave some headroom to preserve the filaments.I will try putting the MCDU on its own tapping on the power supply to see if I can get nearer the design 5 volts.
The 12 volt supply is used for the LED clusters in the ECAM,RMP and ACP panels to cut down the power dissipation relative to 5 volts. I also need the 12 volts for the floor lights.
The extra scree on the left runs FS Commander, Squawkbox,MSN, Active Sky, Teamspeak, & Servinfo. It is also the control station for all the other PC's.
A shot taken while flying online. Sorry about the door handle but I haven't rigged a screen up yet, just experimenting really to settle on the visuals.
Holt McMinn is a sim builder from Australia who popped in to say hello and have a quick fly.
Started work on the gear lever. It is based on a car steering column switch which has a good solid clack/clack feel to it. The knob is turned up from alloy bar and knurled. Just needs a shroud over the spindle end to look like the Airbus lever and some black rubber strip to keep the biscuit crumbs out and the light in.
Gear lever installed and three greens. Will soon be able to throw the keyboard away!
News Flash!
Kensett Air Reveals New Uniforms for Stewardesses
Below - trying out a different screen
Stairway to the flight deck completed
I found this nice little 10 inch touch screen monitor on eBay, I plan to build this into the sidewall of the cockpit on the PF side to handle the simulator services.
It will be used for FS Commander, Squawkbox, Active Sky, vRoute, FS Build, Teamspeak, Servinfo and Trillian (MSN) to start with. Also AST iCFG to set up the displays and VNC to control all of the Sim computers.
A start has been made on the spoiler lever. In addition to the normal movement of the lever the knob is pulled up to arm the spoilers for landing, this is the function of the pull switch. The aircraft also has a light detent at the 50% position, this is the function of the Bales catch.
More pictures here
The pedestal is coming along nicely, need to wire TCAS panel next.
Construction is similar to the radio panels, more pictures here
Sion Rwy 25
Some flight shots
A group of cockpit builders have recently been flying round the world in stages, we started last October 2007 and arrived back at Birmingham on 11th May 2008.
Those who fly on VATSIM might have seen a gaggle of aircraft flying the same route, the aircraft were ASPD01 (Airspeed zero one), BAW33 (Speedbird 33), BAL82A (Britannia 82A), THI02 (Thistle zero two) and MON257 (Monarch 257)
Our penultimate leg was from Sion in Switzerland (LSGS) to Amsterdam (EHAM) and I so enjoyed the scenery flying out of Switzerland that I went back for another flight from Sion into Heathrow.
I thought I would share some shots with you.
Climbout from Sion
Swiss FIR
EGLL Finals
EGLL Taxi
O.K. I know it's only eye candy but it was too wet to garden
this morning so I made a brake pressure gauge.
This is the back of the rudder trim and park brake panel. The large switch on the right is the park brake, a two position rotary switch with a definite clunk clink feel. On the top left is the back of the seven digit disply for the rudder trim and the three position rotary spring back switch for the rudder trim is on the bottom left.
This is the front of the panel, the knobs will be replaced for accurate replicas in due course.
The sidestick boxes have been modified so that the sticks can be recessed into the boxes.
The sidestick is a Logitech Attack 3, I got three very cheap and eBay. They are excellent for the job and well made. The other hole is for the steering tiller. I plan to input the signals from that into the throttle pot connections on the sidestick interface as these will not be used for throttles of course.
This is the stick assembled into the box. You can also see the start of the sidewalls and chart boxes in this shot.
It is possible to buy A320 replica stick tops and it will be easy to fit those later, meanwhile funds are directed to higher priorities.
This is what the sidewalls have to look like when I have finished so some interesting profiles to cut for the interface between MIP, glare and side window sill. I think I'll have to make it in cardboard first!
It is said that once you have got the simulator flying, the priorities start to sort themselves out. I found this too true recently with an online flight which was a disaster of incompetence. I programmed the wrong ICAO code into the FMC destination and wondered why I was trying to fly to Edingurgh whilst the aircraft was trying to fly to Glasgow. Then I dropped my only pencil within reach into the throttle pedestal. The next priority was then to make the closure panels around the throttle and close up any other gaps which makes the pedestal look complete even if there are still switches to wire up.Tthe pencil remains in the bottom of the throttle bay until I next remove it for something or other and I have splashed out on a new one with a built in rubber (for American viewers this in an eraser, not the other thing).
On stand at EGBB
The sidewall, stickbox and coaming structure coming together. Also installed is the speaker and punka louvre forward of the stick. The speaker has its own amplifier mounted behind the panel.
General View 17th August 2008
Back Projection
First trials using back projection. I used a wooden frame and stretched some white fabric over it. Quite good result, no problem with brightness but it is possible to see the weave. Now I need to save up for some proper back projection material which is quite expensive I think.
Picture is Nice/Cote D'Azur Runway 4 left.
Note also that I have finally connected up the MIP back lighting
Top coaming fitted
VATSIM UK Pilot Mentor Bill Casey after a mentoring session on the Simulator with Darren Sugden
MIP Floodlights in manufacture
Screen Test
Spent quite a lot of time lately playing with screens. I was surprised how good the back projection onto fabric is, not quite as sharp as front projection but just as bright. The slight lack of sharpness is due to the weave of the fabric which is just visible if you look at it rather than through it.
I then got a sample of some proper back projection material from DRH (http://www.drhscreens.co.uk/screenfabric.html) which is homogeneous plastic which naturally doesn't have a weave.It is also a grey colour which is supposed to give better contrast. The picture on the left shows the main fabric screen and the sample of plastic screen above (about A4 size). I now have a dilemma in that the image is certainly much sharper but the pixels are now visible which were masked and blended by the weave of the fabric. The pixels are more obtrusive than with front projection and I can only think that this is an effect between transmitted and reflected light. The contrast is slightly improved which takes out some glare.
One thing that is critical is the position of the projector, it must be set low enough so that it is outside direct line of sight; mine is on the floor and the coaming shields the glare. If it is too high this is the result: the bright light on the taxiway is the projector.
Window sills started and glare extensions fitted
The tea trays in manufacture
Unlike the real aircraft we need to use a keyboard when flying online. Up to know I have flown with it on my knee but soon I hope to put it on the tea tray. Also somewhere to study the charts and eat lunch on long flights. They will slide out of the slot under the PFD (see picture opposite)
