X-Keys: F-16 Mini Cockpit

F-16 Mini Cockpit




About The Project:
I started this small workshop project as my introductory step towards my goal of building a full fledge 1:1 scale simulator controls for various Flight Sims and Space Simulators available. As the beginning step i have various restraint on the budget etc. So, i came up with an option to go for a small scale version with minimal cost as possible. Most the parts i used are easily available at any hobby store or stationaries.
This Project took me about a month working only on the weekends.
This Mini Cockpit is made for the F-16 Flight Sim ( Falcon4 AF )


What I have used for my project?

1. X-Keys USB Matrix board :
   This is an I/O Device which can provide upto 128 switches with 8x16 Matrix connections. I ordered it from P.I.Engineering Link
2. Micro Solder :
3. 5mm LEDs :
4. Mini Push Button Switches :
5. Toggle Switches :
6. PCB Boards :
7. IDE Cable and connectors :
8. Cardboards, Favicol and Chart Papers :
   

All the above items cost me around Rs. 5,000 (INR) =~ 100(US$), the X-Keys itself cost Rs.2,800


The Workshop: How I put it all in together?

Schematics:


Distribution Board (DB) Schematics being Designed



Left and Right MFDs Schematics



ICP Schematics

I first jot down the connection and switches schematics before wiring the switches on.



Workshop: DB Board









In this DB Board I sorted the connection that will be coming out of the X-Keys and mapped it to a easy to connect Screw-In connectors with Row and Column connection labeled.



Workshop : MFD Panels












I assigned 5 rows and 4 columns of the X-Keys to this board, and there are 2 of these MFDs.
For rows i have to connect them using a diode to avoid phantom keys.
There are a total of 20+20 = 40 switches in both the MFDs combined.



Workshop : 4-Way Switch






Broke open 2 toggle switches, on is small and the other a larger done.



Connected the lower pin of the smaller toggle with the handle of the larger toggle.









I had to design my own 4-way switch as i was not able to procure it at the moment from the market. I used two Toggle switches and 4 pushbutton switch to make this and used Elastic Bands for the spring.



Workshop : ICP















For ICP I have used 8 Rows and 4 Column to connect to 26 Switches.


Workshop : X-Keys Safe Box






I used a Haldiram Sweet Plastic Box as a safe container for the X-Keys USB Matrix Board. I had to punch few holes in the box and fit the entire thing in there. This was the easiest thing till now.



Workshop : All Completed Boards





Workshop : The Chassis


Front Schematics


Side Schematics


Initial Structure was made with 3 different boxes





All 3 Structures combined together


Back Side with Panels attached and Wired up.


Completed Model







It was a great experience working with this Mini Cockpit, and am now looking forward to start on with 1:1 scale F-16 Cockpit with more Panels very soon.