Bottom Lighting Panel

 Strategies
Kit Bashing


Simulator Supplier Parts
Hispa Panels564 x 72 mm
Sismo Soluciones597 x 85 mm
CockpitSimParts682 x 82 mm
PC Flights562 x 86 mm (measured)


December 2016 prices
Supplierpanelpartstotalnotes
Hispa Panels 412364 €uses small toggle switches
Sismo Soluciones-Module 239incl239 €Assembled
Sismo Soluciones-Panel 45---45 €Panel only (+ components)
Open Cockpits 393574 €
CockpitSimParts 25~ 35£ 60
PC Flights 6339$102
STRATEGIES
To Do:
Shown is the panel as supplied by PC Flights assembled with PC Flights supplied toggle switches
This panel is used to replace the pre-stamped portion of the lighting and engine start portion of the forward overhead frame.
The challenge is to backlight this panel as well as to provide connection to simulator hardware.
KIT BASHING
Isometric view of completed unit.

  • Fabricate 4 new circuit boards:
    2 Circuit boards for lighting the CENTER FORWARD plate. These boards will use surface mount LEDs and mount within the acrylic backing panel.
    2 Circuit boards 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 boards. You may 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 boards.
  • Drill and countersink holes in backplate for attachment of the rear connector circuit boards.



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

    Left LED
    circuit board
    Left LED circuit
    board Mirrored
    Center LED
    circuit board
    Center LED circuit
    board Mirrored
    Right LED
    circuit board
    Right LED circuit
    board Mirrored
    Connector
    circuit board
    Connector circuit
    board Mirrored


    Here is the end result
    Left, Center and Right circuit boards 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 upper and lower LED circuit boards.

    Mount the circuit board and switches to the 2-Bottom acrylic backplates.
    NOTE the countersunk bolts on the middle circuit board.
    Top view of assembled unit. Note the circuit boards and led's between the toggle switches and Bottom panel.
    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