Boeing 737 Panel Dimensions

Anti-Ice Panel

All plates need to be trimmed a little to allow easier fitting.

Backplate
Width	5.75" (approx 146.05 mm)
Height	9 DZUS units (9 x 0.375")
Height	3.375" (approx 85.725 mm)
Backplate Thickness	1/16"
Light Plate Thickness	1/4" (0.25")
Module Depth	6" - 7" (estimated)

Simulator Supplier Parts
Hispa Panels	part of triple panel 145 x 215 mm total
Sismo Soluciones	146 x 86 mm
CockpitSimParts	150 x 85 mm
PC Flights	146 x 86 mm

December 2016 prices
Supplier	panel	annun	parts	total	notes
Hispa Panels	54	incl	22	76 €	with Hydraulic and Door Annunciators (cost for all 3 panels) (small switches)
Sismo Soluciones-Module	89	incl	incl	89 €	Assembled
Sismo Soluciones-Panel	Panel Not Found
Open Cockpits	56	incl	~ 35 (both panels)	91 € (both panels)	with Windows Heat panel
CockpitSimParts	20	incl	~ 6	£ 26
PC Flights	27	12	~ 7	$ 46

STRATEGIES To Do:

Shown is the panel as supplied by PC Flights assembled with PC Flights supplied annunciators and toggle switches

This panel is the correct size although the width between bolt holes seems to be a bit shy of the DZUS standard (as I understand it). This hole spacing allows the PC Flights DZUS replica bolts to fit without interference with bolts on an adjacent panel.
The challenge is to backlight this panel as well as to provide connection to simulator hardware.

KIT BASHING

Isometric view of completed unit.

Get 4 DZUS replica bolts (PC Flights and Sismo both supply them).

Fabricate 2 new circuit boards:

Circuit board for lighting the ANTI ICE plate. This board will use surface mount LEDs and mount within the acrylic backing panel.

Circuit board for external connections including for lights, annunciators, and toggle switches.

Add caps to switch handles (see note below).

Solder LED's and resistors to LED board. You will need to use a probe with 12V in series with a 1K resistor to determine the polarity of the LED's prior to soldering.

Solder the Connectors to the connector board.

Drill and countersink hole in backplate for attachment of the rear connector circuit board.

Post Script files for the surface mount LED & Connector circuit boards

LED and Connector
circuit boards

LED and Connector
circuit boards
Mirrored

Here is the end result	Circuit board with LED's and resistors mounted. The parts are not perfectly lined up, but it's what you get when hand-soldering SMD parts.	The toggle switches are first mounted on the LED circuit board.	Mount the circuit board and switched to the Anti-Ice backplate. NOTE the countersunk bolt.
Top view of assembled unit. Note the circuit board and led's between the toggle switches and Anti-Ice panels.	Wiring to connector circuit board.	Rear view

Switch Caps
Lowes has a product called "White Screw Protectors" for a 1/4" screw (Hillman # 881038). These protectors fit nicely on the handle of a toggle switch although you will need to add a small cylinder of heat-shrink tubing to the narrow part of the switch shaft.

Surface Mounting
Most of the units use CREE CLM1C-WKW-CWBXA453. I wanted 2400mcd brightness, 4500-5650K color temperature, 20ma.
For a 12V supply, I use 2200 ohm resistors when driving 3 LEDs in a string or 3600 ohm for 2 LEDs