Hydraulic Panel

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

Backplate
Width5.75" (approx 146.05 mm)
Height9 DZUS units (9 x 0.375")
3.375" (approx 85.725 mm)
Backplate Thickness1/16"
Light Plate Thickness1/4" (0.25")
Module Depth5" - 6" (estimated)


Simulator Supplier Parts
Hispa Panelspart of triple panel
145 x 215 mm
Sismo Soluciones146 x 86 mm
CockpitSimParts150 x 78 mm
distorted for lower door annunciator panel
PC Flights146 x 86 mm


December 2016 prices
Supplierpanelannunpartstotalnotes
Hispa Panels 54incl2276 €With hydraulic, Door Annunciator (cost for all 3 panels)
Sismo Soluciones-Module 96inclincl96 €Assembled
Sismo Soluciones-Panel 38inclincl38 €Sub Panel Only
Open Cockpits 55incl~ 863 €with Door Annunciator (cost for both panels)
CockpitSimParts 35incl~ 8£ 43with Door Annunciator (incl annun) (cost for both panels)
PC Flights 35129$ 56

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 HYDRAULIC panel. 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 3 holes in the circuit board and use flat-head screws 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 switches to the hydraulic backplate.
    NOTE the additional bolts on the circuit board.

    Bottom view of assembled unit. Note the circuit board and led's between the toggle switches and hydraulic 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