Last Updated: 11/JUL/2023
Building your first Sim....
Let's start!
Hi, I’m Karl, an avionics and mechanical Licensed Aircraft Engineer (LAE), and like many home cockpit builders, my journey started with a simple idea that quickly got completely out of hand!
One evening while working in Brunei, I disappeared down the endless rabbit hole that is YouTube and stumbled across a channel called Build A Boeing. After watching Peter’s videos, I suddenly realised that flight simulation didn’t have to remain trapped behind a computer screen.
You could actually build the cockpit, operate real switches and controls, and have those actions interact with the simulated aircraft.
I was hooked.
The next morning, I excitedly told my wife, Helen, what I had discovered and announced that I was going to build my own Boeing 737 cockpit.
And so the journey that would eventually become 737DIYSIM began.
Why Build a Flight Simulator?
If you already spend hours flying aircraft in Microsoft Flight Simulator or X-Plane, there often comes a point when using a mouse, keyboard and computer monitor just isn't enough.
Moving flight simulation into the physical world changes the experience completely.
There's something incredibly satisfying about reaching above your head to flip a real switch, rotating a physical selector, moving a throttle or pressing an illuminated pushbutton and seeing the aircraft respond on screen.
Instead of clicking a virtual cockpit with a mouse, you're physically interacting with it.
And here’s the important part:
You don't need to build an entire cockpit to experience it.
Modern home cockpit building can start with something as simple as a small 3D-printed panel, a couple of switches, some LEDs and an inexpensive interface board.
Software such as MobiFlight has made it possible for hobby builders to connect physical controls to compatible simulator software without needing to become professional programmers.
Print a panel. Add a switch. Wire it up. Connect it to the simulator.
Then flip that switch for the first time and watch the aircraft respond.
That's the moment when things start getting addictive!
Why Did I Choose the Boeing 737?
My original reason for choosing the 737 wasn't simply because I liked the aircraft.
At the time, I was studying to become an avionics engineer and wanted a better understanding of EFIS (Electronic Flight Instrument System) and the interaction between the various aircraft systems.
I realised that building a functional cockpit could give me an incredible hands-on learning experience alongside my studies.
Rather than simply reading about systems, I could begin to understand how the controls, indications and individual systems fitted together as part of a complete flight deck.
There was also a much simpler reason.
I have always preferred the tactile nature of the Boeing yoke and flight controls over the Airbus sidestick.
So the decision was made.
I was building a 737.
Why Are the Boeing 737 and Airbus A320 So Popular?
Today, the Boeing 737 and Airbus A320 are two obvious choices for anyone considering building an airliner-style home cockpit.
One of their greatest advantages is the sheer amount of information and community knowledge surrounding them.
Over the years, an enormous flight-simulation ecosystem has developed around these aircraft, bringing together pilots, engineers, software developers, cockpit builders and flight-simulation enthusiasts.
That matters enormously when you're trying to build something yourself.
There is little point spending hundreds of hours creating beautiful cockpit hardware if the simulated aircraft underneath it cannot communicate with the physical controls you've built.
That's why choosing your simulator platform and aircraft software is just as important as deciding what you're going to print.
Choosing the right simulator software
Before committing to a large cockpit project, it's important to think about how much of the aircraft you ultimately want to interface.
For full cockpit projects, dedicated simulator software such as ProSim is designed around reproducing aircraft systems and interfacing those systems with external cockpit hardware.
Aircraft add-ons such as the PMDG 737 can also be used by home cockpit builders, particularly for smaller or partial cockpit projects.
The key isn't necessarily choosing the most expensive solution.
It is choosing software that suits what you actually want to build.
If your aim is a switch panel or small desktop cockpit, your requirements will be very different from somebody planning to build an entire dual-seat flight deck with a Main Instrument Panel, pedestal, overheads, motorised controls and multiple displays.
Decide where you want your cockpit journey to go, then make sure your software can go there with you.
Start Small and Build From There
One of the misconceptions surrounding home flight simulators is that you need a huge workshop, specialist machinery and an enormous budget before you can begin.
You really don't.
My original goal with 737DIYSIM was to document my own attempts to build a realistic simulator without spending a fortune.
That philosophy continues today.
3D printing has completely changed what is achievable for the home cockpit builder. Components that would once have required specialist manufacturing can now potentially be designed on a computer, printed at home, assembled on a workbench and connected to the simulator.
You don't have to begin with a complete cockpit.
Start with one panel.
Build an EFIS panel. Add an FMC. Try an overhead panel. Build a set of switches. Experiment with some backlighting.
Learn something from each project and then move on to the next.
Before long, that collection of little projects can begin to look remarkably like a cockpit.
From a Single Panel to a Complete Flight Deck
That's really what 737DIYSIM is about.
It's not about telling you that you need to spend thousands of pounds buying a ready-made simulator.
It's about showing you that you can build it yourself.
Along the way I've connected with an amazing range of builders. Some pursue incredible levels of accuracy, while others simply want to add a few physical controls to their desktop simulator. Some arrive with years of engineering and electronics knowledge; others are holding a soldering iron for the first time.
Both are equally welcome here.
My focus has always been on helping ordinary hobbyists, makers and flight-simulation enthusiasts develop their skills and discover just how much they can create themselves.
You can learn about 3D printing, CAD design, electronics, wiring, aircraft systems, software interfacing and mechanical design, all while working towards something incredibly rewarding.
And you don't have to build everything at once.
Your simulator might begin with a single switch.
Then a panel.
Then another panel...
And before you know it, you're sitting inside something that you built yourself.
Ready to Start Your Own Build?
Whether you're interested in the Boeing 737, Airbus A320, or simply want to experiment with adding physical controls to your existing flight simulator, the most important thing is just to start.
Don't worry about building the perfect cockpit on day one.
Print something. Build something. Wire something. Learn something.
Then connect it to your simulator, flick that first physical switch and watch what happens on screen.
Because that was the moment that started this whole adventure for me.
And it could be the moment that starts yours.
Can you build a sim on a small budget?
Certainly! Let's take a trip down memory lane and discuss my first sim, Sim 1! You don't have to start with a complete Boeing 737 cockpit. Rather, begin with smaller projects such as 737 MCP or radios. While the throttle assembly is challenging, it's an excellent build project! Focus on realism where it matters and as needed. If you decide that this is your hobby, you can expand with various systems as you go. Unless you're confident and have saved money, avoid jumping straight into building a full-size cockpit. It can be expensive and very time-consuming at any level.
Initially, I started with the parking brake light and became fascinated with controlling hardware with software. The introduction of the MCP was a significant advancement, but I must acknowledge that it was also quite challenging. Unfortunately, the necessary resources were not readily available to facilitate the process. This was a huge leap forward for me! However, it took several months to get the initial design to work. If you plan on starting with the MCP, I recommend checking out the DIY MCP v7. It is specifically designed to be easy to build and wire. It comes with a dedicated build guide and youtube video.
Fortunately, I could obtain the wood/timber and monitors for Sim1 at no cost, which was a great starting point. I used my desktop computer to run PMDG, a cheaper but less comprehensive software package for the 737 simulation systems. It's a great budget option. My total cost for building Sim1 was only $600, but the quality reflected that it was a DIY homebuilt project. The majority of the expenses were for Arduinos and electrical components. Luckily, MobiFlight software by Sebastian made the build a million times easier. This software interfaces with the inputs and outputs of electronic hardware to the flight sim software.
I affectionately refer to Simulator 1 as the "baby sim". It was downsized to fit in our previous home, with the captain's side being full size while the F/O side was omitted. Unfortunately, this led to its eventual destruction despite being a remarkable project. I regret having to take it apart for parts to build sim 2.
I encountered an issue with Sim1 when I invited friends to try the simulator. I would set up a scenario where the 737 was at an altitude of 2000 meters and prepared to land, but my friends lost interest after a few attempts because they kept crashing. It would be awesome to have a dual-control cockpit to help guide them onto the runway.
As I progressed to Sim 2, I aimed for a more realistic experience without going over budget. Collaborating with friends who work on Boeing 737s, I acquired photos and dimensions necessary for the project. These resources became the foundation for the plans, designs, and guides available on this website today.
However, despite the stunning appearance of the Sim 2 cockpit, the project ended up as a failure when it came time to assemble the parts. Despite nearing completion, nothing seemed to fit, and I wasted significant time and money. Overnight, I transitioned to Sim 3.
SIM 3 - The Dual Seat Beast
I chuckle now at how sudden the decision to start over was. However, despite the quick decision, it took another eight months before Sim3 began construction.
Six months of my life were spent learning Fusion 360. At least 10 hours a day non-stop through weekends. I became obsessed with designing a whole CAD cockpit, from the smallest screw to the complete design. It completely transformed my approach to building anything! I've realised that CAD/CAM is an essential tool in the design process, as it allows me to perfect my simulations before even beginning the physical build.
I've learned that if it doesn't fit in CAD, it won't fit in real life. I faced a challenge with the glare shield and side window meeting points, which took weeks to resolve. There were moments when I felt like giving up, but I persisted and woke up each morning ready to tackle the problem again.
I'm proud to say that we have successfully built Sim 3, which boasts a beautiful and functional design. It was much easier to build than Sim 1 & 2 with the trim around the base window structure, which is always the most complex part of the process.
For Sim 3, I decided to prioritize practicality over ultra-realistic external features. This approach makes it much easier to add wires or components, as the internal cockpit closely resembles the real thing. At the same time, the exterior design is optimized for ease of construction and maintenance.
During the sim build, I had a great realization when I discovered a unique approach to window construction. The design allows for a layer-by-layer build, similar to a 3D printer, which includes the trim. It's a clever and efficient method.
Is Sim 3 cheap?
In my opinion, I have been pursuing this hobby for almost ten years now. However, in retrospect, the cost of Sim 3 has exceeded $4000, which would not be received well by my wife, Helen. I find this amount astronomical, and I never intended to spend this amount.
I ended up with a Boeing 737 Sim that is not yet perfect, but I am so happy with it. Some have pointed out that my measurements are 5mm off over 2400mm. Nevertheless, I plan to improve this flaw when I obtain my next job at Boeing and can build the sim in real life.
It is not solely the cost of the sim that has made it more expensive than Sim 1. In addition, the sim requires 23 Arduinos, each costing $6.99 (back in 2015, now they are around $20), which was purchased gradually as I needed them.
Regarding the question at hand, "Is Sim 3 affordable?" After reflecting on my five years of work on Sim 3 and witnessing it come to life, I can confidently say it is cheap! The sensation of stepping into the 737 cockpit is amazing. This option is much more cost-effective compared to other hobbyists who insist on using only OEM parts and require an actual 737 cockpit as the framework. To embark on their path, you would need to invest at least $40,000 to construct a functioning simulator - a hefty price tag.
Conclusion
Engaging in simulation aviation is a wonderful hobby for enthusiasts and pilots, as the graphics and software improve in realism and capability each year. While it depends on personal perspective and circumstance, it's worth noting that sims can offer a similar experience to the real thing at a fraction of the cost. My advice to anyone starting is, to begin with small steps and aim high.
Incorporating a 3D printer into your sim building toolkit is an excellent idea, as it allows you to create cockpit panels, parts, and customized components that cater to your specific requirements. Most beginners start by constructing their cockpits using a 3D printer and eventually progress to using top-notch parts as they gain more experience and their budget changes.
However, be warned that you may end up completely engrossed in aviation like me!