Base Platform & Flight Deck Shell

The platform for this simulator was constructed using a framework of 2×4 boards and 23/32” thick plywood sheeting. Deck screws were used for assembly. Twelve swiveling caster wheels were mounted on the underlying framework to provide for mobility without compromising stability.

The dimensions of the base platform were designed to match the size and shape of the flight deck shell with approximately 4 inches of additional space around all the edges. The platform is 96 inches in length. The wide is 100 inches at the aft end and 72 inches at the forward end. It is approximately 4 ½ high with the caster wheels installed underneath.

To allow the platform to be moved inside a home, it was constructed in two separate halves. Then inside the simulator room, the halves were bolted together with five 3/8” diameter bolts. The wood was painted with a flat gray color. Acrylic adhesive was used to install G-Floor vinyl flooring with a slate gray color and small coin pattern. Metal staircase edging was used around the perimeter.

Many home flight simulators, if constructed in stages, begin as an open flight deck. This does save a substantial amount of money. However, adding an enclosed flight deck with windows provides a huge increase in immersion and realism.

This flight deck shell for this simulator was purchased from Flight Deck Solutions. It is made of aluminum panels with a black powder coat finish which are bolted together. The interior dimension and windows are the same dimensions as the real B737 aircraft. The shell is open in the aft part. Polycarbonate windows were installed in each of the six flight deck window openings. A mounting bracket component was installed in the ceiling for the forward overhead panel. This incorporates a hinge that allows the overhead panel to swing down for installation and maintenance, like the real aircraft. Grab handles were also installed above each forward window to assist with moving the flight deck seats forward. Other optional items purchased and installed were oxygen panels and swivel mounted map lights for both the captain and first officer.

A PRO-M Series Liner Set for the B737NG was purchased from Flight Deck Solutions. The set consists of plastic interior pieces painted in beige or gray that emulate the internal flight deck structure of the real aircraft. The windows are clear polycarbonate.

It is best to position and install the main instrument panel prior to installing the interior liner.