The Frame

An exact sized 737 overhead frame was made from Aluminium. The overhead panel gets progressively heavy. Even just the replica light plates start to add considerable weight. When you add wire, switches, gauges, I/O cards then the importance of having a rigid frame becomes apparent. The first picture shows just the frame, the second the light plates have been laid on top to check sizing.

The Back-Lighting

The light plates are added progressively, on this panel miniature bulbs are used in the light plate cavity. This requires a lot of time for wiring, and each plate must be tested. The second picture shows the back of the panel with just the connectivity for the bulbs in place.

Input/Output

Planning the I/O connectivity is very important. There are many cables, in fact 1.2km of cable was used. The primary I/O interface cards were Phidget 16x16 cards for the switching and Phidget LED 64 cards to drive the annociators. Switches and LED's were colour coded and numbered. As can be seen, to shorted cable length as much as possible, the I/O was mounted on the back of the overhead panel. This leaves only x2 USB cables running to the client computer which runs pmSystems.

 All wiring is channelled, and insulated and fused. In total at 12 volts the overhead panel draws about 9amps. A short circuit could damage many different things and at worst cause a fire. Fuses are used to ensure that all lines are protected.

There is also a 28volt supply for the solenoid engine starter switches and magnetic release Yaw Damper and anti ice switches.