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My DHC-6 TwinOtter homecockpit


VTA217

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Hi all,
 
My turn to present the project I started four years ago now... With a back footstep now, I would never imagined this adventure was so time and energy consumer. 
I remember when I started during the easter holidays ... I said to myself it is a three months sprint :D
 
Why the DHC-6 aircraft ?  Just because it is a plane which can be used to go everywhere in the world.  With wheels, skis, floats and even amphibian versions ... we see this aircraft in situation where it is the only one really able to go there : Antarctica,  Lukla (highest airport in the Himalaya), Saba (shortest runway in the Carabeans), Tapini (a moutain valley in the New Guinea), the Maldives (where we can find the biggest DHC6 float planes base), the Marquises islands in French Polynesia... and a lot of other areas you probably know. 
Thus, for me, it was an evidence that this plane is the most appropriate for a simer to play everyrwhere without being bored...
 
Like most homecockpit builder, I started by a lot of research on the web.  I quickly realized that the DHC-6 TwinOtter does not exist...  And that everything has to be built !!
Apart the radiostack with the GPS GNS530 and the common radio elements which can be found, all the rest does not exist for simer...
 
After a couple of months of reflexion... i finished to stay on a balance between screens and buttons (to average the money spent too).
 
Rapidly, I selected :
 
  • the P3D flight simulator I was already using   (now i am looking to switch to the new FS2020 simulator which is fantastic for VFR I need with the Twotter)
  • The Aerosoft DHC-6 TwinOtter Extended  because it seems the best for a lot of simers
  • AirManager tool from SimInnovations to display the gauges on screens
  • IOCards from a French electronic provider (OpenCockpits compatible)
  • Joystick cards from the same electrronic provider EFDE (efde.fr)
  • On demand built components from HomeCockpit.fr
  • All the rest built from wood and plexy
 
 
 
Quickly I realized I will not have the space to build a complete cabin with both left and right seats...
So my homecockpit will be the left seat and the center console
 
From the sizes I got from the web, i choosed to use 17" screen monitors in landscape for the captain instruments and another one in portrait for the engines gauges
 
 
https://nsm09.casimages.com/img/2018/06/18//18061809493013220415767738.jpg
 
 
Then some plexy with holes to see the gauges.  This facade is the captain instrument one.
The alerters have been made by HomeCockpit on demand for my DHC6.  They are based on existing Airbus korrys  (some can be pushed).
The AP has been designed by myself and built by HomeCocpkit too. Like the Fire Panel (picture below)
The bezels (to decorate the holes with a real instrument look) have been 3D printed by EFDE. 
 
https://nsm09.casimages.com/img/2018/11/20//18112010381213220416004693.jpg
 
 
 
The engine panel face with the on demand fire panel and its fire handles light
 
The 3D printed small engines gauges bezels (EFDE) and the front lights (the little columns with a warm white LED) to illuminate from the front like on the real plane 
 
 
 
https://nsm09.casimages.com/img/2018/11/16//18111610120413220415998570.jpg
 
The box below was one fuel selector panel I placed here to hold the buttons at the normal place  (like the real plane) ...
But I was not happy and I removed it to build a fuel selector placed BELOW the engines panels... this is the limitation of using a screen..
 
 
 
 
 
Thus the prototype became like below ; It was encouraging 8-)
 
https://nsm09.casimages.com/img/2018/11/20//18112010381113220416004688.jpg
 
The DHC6 gauges are gauges built by a French friend who has finished is TwinOtter for the specific ones, the others are SimInnovation free gauges General Aviation ones.
 
Here to unload the PC of extra display needs with graphic card outputs and CPU load,  I choosed to use a new AirManager functionnality (it was new two years ago O_o ) : The Raspberry Pi
 
Here we have one Raspberry Pi connected to the left screen and another Raspberry Pi conencted to the engines screen.  *
It is smooth and totaly frees the PC... AirManager loaded on the nano computers receives the simulator in live over the network and represent the data with the appropriate gauge.
The work is done once, we do have to think after.  The Raspberry are doing their lives themselves !!  A very good solution for a homecockpit solution I think !
 
I use even a third raspberry to display the battery gauges.  In the photo below, you see the 3D cockpit view and below the real display of my homecockpit.
The difference here is that the  screen is a 10" one encapsulated on the Pi
 

https://nsm09.casimages.com/img/2018/03/27//18032710344213220415635606.jpg

 
 
You can see closely the 10" Pi screen with the battery gauges before the "decoration"
 

https://nsm09.casimages.com/img/2018/12/12//18121206230913220416034735.jpg

 
 
 
 
 
 
 
 
 
 
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For the fuel selector, like most thing, I finally ordered 3D printed components... it is very pro in the look and not too expensive... at least I gain time somewhere with a good result !!
 
EFDE provided me even the multiselector switch (blocked here on 3 positions)
 
https://nsm09.casimages.com/img/2018/03/26//18032612430113220415632393.jpg
 
 
Same for the encoders ;  It is a made by EFDE and are particular because very thin... they then be behind the face but above the screen!!! They are very flat !
I discover the solder process (I was not an expert and still not an electronic expert...)  ; I used color IDE like cables for me to identify on the other side, the IOcard one,  which cable is which one...
As you can see we have 6 wires.  2 are used for the encoder ; 2 for the push button of the encoder (I will not use it probably but i prefer to wire this function while it was on the table..I do not want to dismount later... and 2 wires for the +5v power.
 
https://nsm09.casimages.com/img/2018/03/10//18031009051713220415607109.jpg
 
On homecockpit builders recommandation, I used IDC plugs to be able to disconnect "in case" without have to remove all the wires from the IOcards....
 
 

https://nsm09.casimages.com/img/2018/03/10//18031009051713220415607110.png

 
 
 
Here you can see the  naked bezels and the flat encoders mounted on with 3D printed buttons (VOR, HDG...)
 
and one of the IOcards I have.  I choosed the quick wire option, it is easy to plug the cables pushing the orange lever on each pin#
On this card we have 32 inputs (buttons) and 32 outputs (leds) .   They can be combined up to 4 per group. 
Thus you have 64 with 2 cards, up to 128 IN/OUT with 4 cards ; Each card (or group of cards) is conencted via USB plug to the PC
 
https://nsm07.casimages.com/img/2018/01/14//18011409071513220415460166.png
 
 
 
Rapidly, I remarked I will need some stable power in 3v, 5v and 12v (for the backlight)...
 
I have mounted an old PC power with distributors for me later to peek the adequate voltage behind the screens
 
https://nsm09.casimages.com/img/2018/02/18//18021808294613220415566334.jpg 
 
Very practical !!! By now in practice... i do not use the 3v one... but who knows ?   8-)
 
 
 
 
 
 
 
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The GPS GNS530
 
 

One of the big work I made was the GPS ... I choosed a kit from Simwarekit, a US vendor from who I have bought a GPS GNS530 kit .... everything was provided... but everything has to be sold !!! I still do not know why I choosed that track because I was not an electronic amateur.... but I probably said to myleft "it is cheapest than buying an existing device" ... If today I will have to select a GPS , I will use one from a company specialized on that like the US one RealSimGear, Ruscool and others..


The components
 

https://nsm07.casimages.com/img/2018/01/22//18012211451913220415492352.png

https://nsm07.casimages.com/img/2018/01/22//18012211451813220415492351.png

 
 
 
 
as you can imagine, I got a real moment of solitude when I received the GPS kit .... :D
 
I asked my 3D printer provider to build the frame and buttons.  First the buttons where in PLA, but he got a new machine able to use resina and the button are better with !!
 
 
https://nsm09.casimages.com/img/2018/03/18//18031810101713220415620247.jpg
 
 
https://nsm09.casimages.com/img/2018/12/18//18121812071813220416040449.jpg
 
 
The kit is based on an Arduino MEGA
 
https://nsm09.casimages.com/img/2018/12/30//18123009293813220416054549.jpg
 
 
Finished it is like that :
 
https://nsm09.casimages.com/img/2019/01/31//19013110355313220416100513.jpg
 
 
Behind a 10" screen connected to the PC.  Then the RealityXP GNS530 addon is used to power and replace the existing GNS530.  The GPS window is just undocked from the 3D cockpit view and moved to the external GPD screen.  Then we save a default flight and the GPS screen retrieve its place correctly next flights.  Same trick for FSX and P3D.
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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The Radiostack
 
The other step was the radiostack but I am stuck and postponed it until now.... The plexy cut I did was very poor quality... holes are quite easy to be clean but not lines... But now my EFDE provider is able to laser cut... So i have to define my exact needs and it will be made with a professional look !!


I tried too many solutions... even for the words to put... stikers, printed paper between two transparent faces... not happy of myself !!

The IOcards with the DIGIT option and the digit groups already mounted by the provider (i like him)
 

https://nsm09.casimages.com/img/2019/02/09//19020912382213220416113705.jpg
 
 
I just build this the mixer panel (top one in the radio stack)  using micro push with leds
 
https://nsm09.casimages.com/img/2019/02/03//19020311464013220416106663.jpg
 
 
https://nsm09.casimages.com/img/2019/02/09//19020912382213220416113704.jpg
 
 
 

 

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The compass

End of the year around november, I asked my provider if he was able to 3D print a compass with the DHC-6 look around its own compass solution he provides (IO servo card).

He said YES !!!


the real
 

https://nsm09.casimages.com/img/2019/12/21//LbLIIb-dhc6-compas-l1600-1.jpg

 

His 3D sketches
 
https://nsm09.casimages.com/img/2019/12/21//MbLIIb-compas-panneau-cal.jpg


https://nsm09.casimages.com/img/2019/12/21//MbLIIb-couronne.jpg

 
 
and the fake real



inside wheel
https://nsm09.casimages.com/img/2019/12/21//MbLIIb-compas-couronne.jpg

 
 
the full compas even with a backlight inside like in real !!
 
[img src="

" style="max-width:100%;" alt="https://nsm09.casimages.com/img/2019/12/21//LbLIIb-compas-final-profil.jpg " src=""][/div]

 
 
It was amazing to receive this for Xmas !!!
 
Not yet mounted because I need to find a way to fix it with the left and right announcers groups...
 

 

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The flaps annonciator

I asked Fabien from EFDE if it is possible.... he said yes... I already have a LEDs train for B737 ... i will adapt for your flaps indicator

https://nsm09.casimages.com/img/2020/01/07//YBUOIb-Compas-flaps-indicator-flaps-15.png

here is the LEDs train

https://nsm09.casimages.com/img/2020/01/07//YBUOIb-EFDE-carte-FLAPS-.jpg
I asked him to 3D print a mask and I got that :

https://nsm09.casimages.com/img/2020/01/07//ZBUOIb-flap-Sans-cache-VS-cache.gif

 
 
 
 
yet not mounted because i need first to mount the compass... which needs the left/right announciators groups...
 
 
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The overhead

One particularity of the TwinOtter is that the engines handles are on the roof and we have some buttons on a overhead box like this
https://nsm09.casimages.com/img/2020/02/09//tVPaJb-manettes3-forum.png

I first made the handles from wood....; But after two years and knowing now that with a 3D printers it could be like the real ones, I submited the 3Dprint of the overhead handles (but the throttle ones, I keep mine in wood because of the reverse mecanism I imagined)
https://nsm09.casimages.com/img/2020/02/09//tVPaJb-manettes-3D-forum.jpg


Because my provider is now able to laser cut... it opens a new possibility for me to have engraved panels with a real professionnal look and the backlight feature !!!

Thus this winter, I submitted all the quotations for him to rebuild my first overhead panels version with a laser printer !!

While waiting for the realisation, I prepared the laser panel back on a white 3mm thick plastic (it will better spread the light from behind the cockpit builders said)
https://nsm09.casimages.com/img/2020/02/09//qwSaJb-IMG-20200119-123941.jpg

The top panels to be replaced... https://nsm09.casimages.com/img/2020/02/09//rwSaJb-IMG-20200125-163336.jpg

with those :https://nsm09.casimages.com/img/2020/02/09//qwSaJb-IMG-20200125-143352.jpg
And mounted with the buttons it rocks !!! I am very happy of this achievement

https://nsm09.casimages.com/img/2020/02/09//rwSaJb-IMG-20200125-164817.jpg
 

I made the same for the remaining panels ...
 

https://nsm09.casimages.com/img/2020/02/09//swSaJb-IMG-20200208-150327.jpg

 
 
https://nsm09.casimages.com/img/2020/02/09//swSaJb-IMG-20200208-150340.jpg
 
 
I decided to use the breaker panel in a smart manner :  instead of putting 3d printed factice breakers buttons, I easily found  micro push buttons with the quite same aviation breakers appearance:
https://www.gotronic.fr/cat-boutons-poussoirs-miniatures-economiques-525.jpg
 
 
Thus I have put 32 push buttons on this panel.  They will be used for the simer side... to send a keyboard function key instead of taking the PC keyboard & mouse..  it is the idea...
 
 
Here it is :
https://nsm09.casimages.com/img/2020/02/10//CZmbJb-IMG-20200210-163908.jpg
 
 
and with a backlight test
https://nsm09.casimages.com/img/2020/02/10//BZmbJb-IMG-20200210-163842.jpg
 
 
 
 
 
Below the levers throttles, feather and fuel tap
 
https://nsm09.casimages.com/img/2020/02/10//MTmbJb-IMG-20200210-122611.jpg
 
 
The start panel with the new laser face
 
https://nsm09.casimages.com/img/2020/02/11//1aCbJb-IMG-20200211-111622.jpg
 
 
 
General overhead view 
 
https://nsm09.casimages.com/img/2020/02/19//qn8eJb-IMG-20200219-205134.jpg
 
 
 
 
You can see the mecanism on the trottle levers :  in the real plane the pilot can twist them to unlock the levers to ba able to go backward ... in beta mode... the revserse one
 
 
So I put an electronic door lock on each throttle lever.  A microswitch on near the handles will act when the handles are twisted.  Then the door lock will open and the lever can go backward..
It is the cinematic...but not too proud of the realisation in term of esthetic....  I will probably found a 3rd throttles version one day :D
 
 
 
Behind the scenes :
 
https://nsm09.casimages.com/img/2020/02/17//4mNdJb-IMG-20200217-015434.jpg
 
 
3 IOcards for the switches
1 joystick card for the levers  (2 input for throttles, 2 input for feather).  The fuel tap has switches and no potentiometer.
 
 
 
 
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The TEST panel

https://nsm09.casimages.com/img/2020/03/05//oiMjJb-test-panel.png
https://nsm09.casimages.com/img/2020/03/05//niMjJb-IMG-20200303-230205.jpg

 

The FUEL SELECTOR panel


https://nsm09.casimages.com/img/2020/03/05//QvMjJb-engine-bottom.png

to replace this one :
https://nsm09.casimages.com/img/2020/03/05//PvMjJb-IMG-20180330-234455.jpg

 
by this one:
 
https://nsm09.casimages.com/img/2020/03/05//QvMjJb-IMG-20200303-230112.jpg


The FLOAT panel (used for amphibian version)
 

https://nsm09.casimages.com/img/2020/03/05//S6MjJb-DHC6-panel-FLOAT-wheels-up.png
 
 

https://nsm09.casimages.com/img/2020/03/05//S6MjJb-IMG-20200303-230246.jpg
I changed the top LED from yellow to blue because they are blue in the real aircraft !!

The gear level will be used for the ski gear too...


The Announciators

 
 
Soldering the announciators....
 
https://nsm09.casimages.com/img/2020/03/15//dq9nJb-IMG-20200314-174804.jpg
 

https://nsm09.casimages.com/img/2020/03/15//dq9nJb-IMG-20200314-174450.jpg
https://nsm09.casimages.com/img/2020/03/15//dq9nJb-IMG-20200314-200453.jpg

 
 
I remarked here that the lights were  not very efficient for the reading ...
 
https://nsm09.casimages.com/img/2020/03/15//O99nJb-IMG-20200314-200645.jpg
 
 
Dispite the fact I bought this and it was made for me on demand... i decided to open the box ..
 
 
2 oranges LED per announciator....
 
https://nsm09.casimages.com/img/2020/03/15//O99nJb-IMG-20200315-102702.jpg
 
 
not enough I said
 
I added a third LED in each annonciator box
 
https://nsm09.casimages.com/img/2020/03/15//R99nJb-IMG-20200315-175242.jpg
 
 
 
 
 
Better read now :
 
https://nsm09.casimages.com/img/2020/03/15//Q99nJb-IMG-20200315-165054.jpg
 
 
 
even in the dark
 
https://nsm09.casimages.com/img/2020/03/15//R99nJb-IMG-20200315-191456.jpg
 
 
 
 
 
 
 
 
 
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The flaps gauge is on situation, working, but not yet fixed with the appropriate windscreen mount I have to build... 

 

The compass is mounted in his final box with the annunciators blocks. They are wired but I have to write LUA script to illuminate the leds.

The compas is working well. The micromotor is turning the crown and is displaying same degrees as the cockpit 3D like you can see in the photo below.

it is amazing to see the compas moving same as in the cockpit 3D of my fovourite addon :)

wiC4Jb-compas-vs-cockpit3D.jpg

 

 

 

 

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BTW I am quite blocked looking for measurements from real DHC-6 machine but I do not find a pilot or a mecanic for that...

 

If you know someone you know someone who can do one (or all) of those measurements, I will really appreciate it !!

 

Please login to display this image.

 

I'll keep you in touch to let you know how I continue this project of cabin.

 

Thanks for reading

Philippe

 

 

 

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10 hours ago, MarkHurst said:

 

This is all amazing, but your prototype continues to be my favourite pic :)

 

Thanks Mark.  I'll take it as an encouragement :)

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  • 2 weeks later...
  • 2 weeks later...

Thanks a lot.  If you appreciate, it is because it looks like something :)

 

I hope during xmas vacations, I'll be able to restart my suspended sim work during last summer.

 

And yes I'll keep this post updated !

 

Have a nice continuation

Stay Safe

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  • 5 months later...
13 hours ago, flyerdu973 said:

What a Good Work !!! :)

 

Thanks Marc !

 

I realized because of lack of time from my side and also lack of "how to do" ,  that submitting the work to dedicated providers/builders/3D printers is maybe costing more but the result is here. And I have then "just" like a LEGO brick to assemble.

 

The good news during all this (lets say) "sim lockdown" is that ifinally found a DHC6 mecanician who took time to take photos and mesurements i missed. 

 

On the sim side, FS2020 is ready with a lot of scenaries.

The great tool FSUIPC (used to interface and script the sim) is also available for the new FS release

We know that we are in a very good shape for the aerosoft FS TwinOtter addon. it looks to turn in final ;) 

I am using AirManager from SimInnovation and they just did the FS compatible release 4 but without the "LVars" implementation (if I well followed). 

Cockpit builders need those to interface the addon with the "real buttons and lights". 

 

Now the ball is in my side for the (re)building part.  

 

I hope to give good news in the comming months  (four years started now.. it is long...)

 

Bye

Philippe

 

 

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