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#4483335 - 07/19/19 08:22 AM Making Cockpit Panels PLOG  
Joined: Apr 2014
Posts: 7
Tekadept Offline
Junior Member
Tekadept  Offline
Junior Member

Joined: Apr 2014
Posts: 7
Hi All,

I thought I would go through my process of manufacturing some plates / Panels for various Fighters, and hopefully somebody can get something from my experiences, and provide some feedback.

First thing I am working on is panels for F/A-18C for DCS.
Firstly I have sourced some Tiff Images, and tweaking my sizes from that 146mm standard width, DZUS 9.375mm Spacing for holes.

One thing I am not a fan of the F16 or MS 33558 Font. I am going to be use a Gorton Heavy font which looks far better to me with less work required for letter spacing etc and I’m happy with.

Firstly everyone seems to use acrylic, so I have gone through and done some various testing and picked up some Clear and White acrylic. I did my first test on clear acrylic, got some rattle can Rustoleum 2X paint, and gave it 2 coats.

This is the Result

Now this doesn’t look to bad at first glance, the text is a bit fuzzy, the white frosted look from the engraving is visible but not vibrant. The Spray can on inspection is a gloss which doesn’t look that great either.

So now I throw some lights behind this bad boy to see how it backlights.
[Linked Image]
https://i.imgur.com/CdT5PhN.jpg
Oh yeah serious problem right here, Despite 2 coats light leaks like crazy and would require 3 or 4 coats..
Lets scrap that idea.

Now I move on to a White Acrylic, this time the ExtPower Panel. Instead of using the Rattle can paint, I use some acrylic Primer, and crank out the spray gun and use a Flat black Water Based enamel 2 coats.
[Linked Image]
https://i.imgur.com/bwbg9Hi.jpg

Now this looks better already, the text engraves crisper, the white shows through and looks a bit better, and I also like that flat black vs the cans gloss.

Lets see how this backlights?
[Linked Image]
https://imgur.com/uq3ffDd.jpg

I think this looks much better, still a bit of light leakage but nowhere near as bad, and I think that’s because I did not have a even spray. With a better even spray job I feel the 2 coats would suffice.

Definitely getting some hotspots through with the LEDS so that is not the best.
Lets try a Different panel see if the results get better.. This time the Snsr Panel, I took more time with spraying, still only 2 coats, but making sure I got better coverage.
[Linked Image]
https://imgur.com/oG2k1Lv.jpg

The light leaks are no longer there, but still getting the hotspots, and looking at the non-lit version below the surface does look ok, but it is VERY easily scratched and they show up quote noticeable (this is light fingernail rubbing over it).
[Linked Image]
https://imgur.com/llqmtxG.jpg




Last edited by Tekadept; 10/13/21 08:40 AM. Reason: Imagesize

"Lead me, follow me, or get the hell out of my way" (Gen. George Patton)
https://www.tekcreations.space
Inline advert (2nd and 3rd post)

#4483462 - 07/20/19 09:38 AM Re: Making Cockpit Panels PLOG [Re: Tekadept]  
Joined: Apr 2014
Posts: 7
Tekadept Offline
Junior Member
Tekadept  Offline
Junior Member

Joined: Apr 2014
Posts: 7
Ok after some rather unsatisfactory Results using Painted Acrylic,


Now I have discovered some acrylic called OPAL 445. this has a light transmission of 50% as is designed to diffuse light efficiently for the signage industry.

Now I have picked up some Opal today, and plan on doing some more cutting tonight and see how it goes, utilising the 1.6mm Engraving with a 3 plate design.

I Will post those results when finished.

Last edited by Tekadept; 10/13/21 08:41 AM.

"Lead me, follow me, or get the hell out of my way" (Gen. George Patton)
https://www.tekcreations.space
#4485325 - 08/06/19 11:55 PM Re: Making Cockpit Panels PLOG [Re: Tekadept]  
Joined: Apr 2014
Posts: 7
Tekadept Offline
Junior Member
Tekadept  Offline
Junior Member

Joined: Apr 2014
Posts: 7
After previous attempts, I have now refined what I am doing from a design standpoint
I have done the F18 Hornet Sensor Panel below
[Linked Image]
[Linked Image]

The Whites are nice and bright unlit, and the black that nice even finish.. Just wondering with the Rotaries whether I really need the white circle… that will all depend on if I can come up with some illuminated knobs, probably best to include it now as it is only an extra 20 seconds of engraving time.

Now what I have done as mentioned before, I am sticking with a 3mm Base plate, this time using the new Opal 445 Acrylic. Putting this and and doing some back lighting the difference is quite remarkable. Below is a shot illuminated with 5050 SMD LED strip through a layer of 2 x 3mm layers Opal and with a ambient light on in the room.

[Linked Image]
And Below is a shot with the light turned off and only light from the monitor.


[Linked Image]

There is nice even light transmission and no hotspots. Now there is brighter spots, but that is because I am literally just placing 2 strips of LED’s underneath with no thought to placement like I will will the final panels. With proper placement I am confident everything will be evenly illuminated. I also have a 3528 strip to trial later on.

Next its time to go through and do cuts and determine what panel layout I will use between the 3mm and the 2mm.. Doing some Math, the base and middle as 3mm with the 1.6mm top makes it 7.6mm overall (which I think is getting a bit on the high side (although close to the real overall height of a set of panels according to my research). If I go the 2mm that makes it 6.6 which I think is a nicer overall height.

Will post some pics once I finish off and put some switches in to see how they sit.

Last edited by Tekadept; 10/13/21 08:42 AM.

"Lead me, follow me, or get the hell out of my way" (Gen. George Patton)
https://www.tekcreations.space
#4486077 - 08/13/19 05:53 PM Re: Making Cockpit Panels PLOG [Re: Tekadept]  
Joined: Dec 2009
Posts: 748
AndyB Offline
Member
AndyB  Offline
Member

Joined: Dec 2009
Posts: 748
Ayrshire, Scotland
Hi Tekadept,

Panels are looking very good. I assume you are going to paint the edges of the top two as well to avoid light bleeding out.


Keep up the great work.

Andy

Last edited by AndyB; 08/14/19 06:00 PM.

Andy's simpit: http://www.simpit.me.uk
#4486943 - 08/21/19 03:52 PM Re: Making Cockpit Panels PLOG [Re: AndyB]  
Joined: Apr 2014
Posts: 7
Tekadept Offline
Junior Member
Tekadept  Offline
Junior Member

Joined: Apr 2014
Posts: 7
Cheers AndyB,
Yep will definitely be masked off and hit with paint to stop the light bleed

I have gone through and done some more work, first up the ECM panel

[Linked Image]
[Linked Image]
Here I went for some Mattisse Acrylic paint to infill for the hazard striping. This looks better than spray paint I think. I have some thin adhesive material on back order, but until that comes in to experiment I'm happy withthis result.

Here is the ELectrical Panel. I have a stepper motor gauge on order to play around with before I do any housings etc for this panel
[Linked Image]

Flight Control system panel done, just need to get a flip toggle cover, but the sizing I went for matched all the standard ones I saw online.
[Linked Image]

Exterior Lights redone
[Linked Image]

Ground Power, here the NATOPS didn't show "auto" , but DCS does.. without knowing why NATOPS has it missing I went for whats in DCS.
[Linked Image]

APU sorted, this is one that will need the post paint on the bottom plate to mask off I believe.
[Linked Image]

Interior Lighting done..
[Linked Image]

Next panels to work on is the Master Arm Panel and KY58 and the comms panels...


"Lead me, follow me, or get the hell out of my way" (Gen. George Patton)
https://www.tekcreations.space
#4486992 - 08/21/19 08:56 PM Re: Making Cockpit Panels PLOG [Re: Tekadept]  
Joined: Dec 2009
Posts: 748
AndyB Offline
Member
AndyB  Offline
Member

Joined: Dec 2009
Posts: 748
Ayrshire, Scotland
Hi Tekadept,

Your panels are looking superb. Can't wait to see them in place and backlit.

Could you go in to a bit more detail on how you did the black/yellow/white hatching on the area around the "ECM JETT" switch ? I'm going to have to do something like that in my own pit eventually and any advice would be great. My panels are all currently just printed paper on perspex and are not backlit. The ink on the paper is now turning purple with the uv of the sunlight (yes, we do get it here sometimes....) and I was planning to make new ones. I purchased a cheapo chinese cnc engraver and upgraded it a bit, but it's slow going. Bloody life keys getting in the way !

Keep up the great work buddy,

Cheers,

Andy


Andy's simpit: http://www.simpit.me.uk
#4487734 - 08/28/19 12:01 PM Re: Making Cockpit Panels PLOG [Re: AndyB]  
Joined: Apr 2014
Posts: 7
Tekadept Offline
Junior Member
Tekadept  Offline
Junior Member

Joined: Apr 2014
Posts: 7
Cheers thanks

To do the hatching, all I did was do the pattern with the right spacings etc (be mindful you don't go too thin for the gaps, I did that first and the black was just to thing it ruined the effect)

Then engraved every single of them them to show the white, then I placed masking tape over the top, and then did an outline on the ones that needed to be yellow.

Then I hit it with a spray of enamel paint and peeled off the masking tape carefully whilst its still wet.

Yeh I hear ya that life thing is a drag, if only we could get paid to do the hobbies we enjoy smile


"Lead me, follow me, or get the hell out of my way" (Gen. George Patton)
https://www.tekcreations.space

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