Building a Boeing 737-800 is one of the most challenging activities I’ve done in my whole life. If you want to be successful, you need to know a lot in the following areas (or do several months of internet research as in my case):

• Construction engineering
• Electricals
• Software programming (that’s my main area)
• Flight experience on a Boeing 737-800 – the most complicated point

Let’s have a look on each of these topics.

Construction engineering
When we speak about building a full scale flight simulator, we are talking about building the whole (!) cockpit shell in REAL dimensions. In my case I have a dedicated room in the basement of my house (which we build in the year 2007…), which has enough room for a whole cockpit shell. The main structure of my MIP (main instrument panel) currently consits of MDF panels (MDF is the english word for “Spannholzplatten” in german ). Now you would ask: and from where I get the real dimensions of the cockpit shell? Answer: internet research!

The big problem here is, that you can’t search to site xyz, and read everything about building cockpit shells. You need to visit several different sites, and combine their concepts to your final solution, which works best for you. There is no complete solution which fits for everyone – unfortunately. But that’s the great aspect of doing such things: reseraching, making prototypes, checking them against requirements and refine them, until you have found the ultimate solution.

Electricals
Another very important thing about building flight simulation cockpits is hardware engineering. You are working directly with the bits & bytes of your hardware switches instead of using great APIs (application programming interfaces) around these “input types”. In my case it took me several weeks, until I was able to use a hardware switch (bought at the electrical shop Conrad) to move up and down the gear – but it’s amazing when you have done it the correct way. In subsequent weblog posts I’ll look at the different hardware switches you will need at least to build a fully functional cockpit. You also need to know something about the inner workings of electronics and your used hardware switches, because when you have problems, you can’t just attach a debugger and debug the problem. Here you are working with wires and voltage!

Software programming
As soon as you have build your hardware interface, you have to program the whole thing to interact with the real flight simulation software – in my case with Microsoft Flight Simulator X. I have a long history with Microsoft technologies and especially with the .NET framework, therefore I’ve build a managed interface wrapper assembly around my hardware switches, with which I can interact with the switches and output controls (like LEDs) in an event driven approach. If you do not know something about software programming, don’t try to build a home cockpit.

Flight experience on a Boeing 737-800
That’s the most complicated part to achieve in real world, and after 9/11 it’s very hard (or let’s say: impossible!) to get in any cockpit during the flight :-(. You have only 2 options here:

• Research through the internet: there are great Boeing operation manuals available for download, but they are just describing each switch in the cockpit. They don’t tell you the interdependencies between the switches and how one switch will affect another one in the cockpit.
• Try to find a friend (or a person who will be your new friend) who is flying a Boeing 737-800. I’m currently going for this way, and talking to any pilot I can see when I’m on my business trips. Unfortunately our local airline (Austrian Airlines) only flies A-319 & A-320 within Europe (short haul distances) and B-767 & B-777 to US, Australia, China (long haul distances) etc. So currently I have no access to a person who flies the 737-800.

In the next weblog post I’ll describe the several hardware and software partners I’m working togehter to build this amazing project.

-Klaus