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OK, how do you turn this into a B737NG side window
assembly easily? Quite simply you don't. The Windshield assembly is
the most complex part of the shell, so I decided to start there.
What I did was to build a basic frame using straight angles and I will
'round' the two back window angles using the trim sheets.
Well I'm happy with the way that the
side windows turned out. They are virtually identical to the drawing
with the exception that to make all the dimensions fit together, I
have had to be a little 'artistic' with a couple of the angles. No
problem though, I will simply make a few 'adjustments' when it
all goes together.
The plan is to start at the back of the cabin and
work forward. I am planning to build each piece as a
component frame before final assembly and panel trimming, which
I think is going to be the difficu lt
part. So this week I have started on the
rear bulkhead and cabin entry.
Today
is the 18th August and I've built the Cabin Entry Door Frame,
the Observers Seat and the Rear Avionics and Systems Bay Frame.
If you want more information on the Aft
Flightdeck CLICK HERE.
Well I got real lucky today (25th August
2005), I
was originally going to build a couple of seats, but quite by
chance I found in our local scrap yard a 2000 FIAT BRAVA
which had 2 x very nice Dark Grey i.e. the same colour as the
cockpit, Front Seats and at GB£15 (about 22 euro or $27) I had
to take them.
I will have some Sheepskin
Liners in place this week. What I've also done is take the rear seat because
it splits 1/3-2/3. I will use the narrow side for the observers
seat. NICE ONE :o)
June 3rd 2006 This week I spent my time sorting out the
Avionics.
Now we have proper control over the way we communicate and a couple of
'Added Extra's as well :o)
June 10th 2006.
Well i finally got round to painting the Knobs all one colour on the
pedestal. Much better. But I still have to fit the weather
radar, cabin door and rudder trim plates which have arrived from
HISPANELS (but still waiting for the CHRONOGRAPHS). Apparently, Manolo
at Hispapanels has had a problem with his engraver. But God Love
Him, for the inconvenience, he has given everybody with an outstanding
order a 15% discount :o).
June 17th 2006. Well i
finally got to paint the side windows and the windshield
centre post because i needed to have the Overhead Panel in place
to work on it. So i made a 'temporary frame' and now we are
getting the impression that we are in a cabin.
I have now wired
up the power for the overhead floods and Radio Speakers and they
have been tested and work fine. Once I have finished
the overhead wiring, systems and annunciation, i will be able to
concentrate on finishing the shell.
It's looking good and things are starting to
move along nicely.
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Wednesday 5th July 2006.
Now the Overhead Panel is installed (albeit temporarily) and
working, work needs to progress on the shell and the windows.
So, yesterday, armed with a drawing, a pile of wood and some
tools, I set about trying to create a masterpiece like this.
I
should have gone to the Pub !. If anybody tells you that
building the windshield and side windows of a Boeing 737NG
is easy, don't believe a word of it, it's a B*****D !. I
know, i've been there. But dogged determination and
a will to succeed gets you going in the right direction.
Electronics, Computers and Technology do not defeat me, but I
have to take my hat off to you guys who can master the art of
shaping wood into sophisticated art forms that your wife doesn't
want to light the barbeque with.
So, two litres of blood later and some swear words i didn't know
i knew, we are getting somewhere. Out of nowhere ,
miraculously has appeared a shape that resembles the two front
windshield panels. I may have been a little
over zealous with the centre support, but it has to support a
lot of weight. And of course there's still time to change the
design. 
Thursday
6th July 2006 Ok well i'm on a roll. So what
the hell, lets have a go at the side windows. Now there's
confidence for you. Confidence is another word for
it's only going to take me three attempts to get it right
instead of four (LOL) ! 
Sunday 9th July 2006
This weekend, I managed to get the windshield off the floor and
mounted. Then i started on the windows. Other things seem
to take up so much time, but we are determined to get this shell
finished in the next month or so. To mount the windshield i had
to move the projector from it's temporary home, so i actually
got round to mounting it properly. Glareshield is finished
and all trimmed.
Thursday 13th July 2006
Got the side windows finished and mated up to the windshield.
Now we are onto the roof frame. Having a few problems because
there are some very tricky angles to cut, so i've started on the
easy bits :o)
Wednesday 10th April
2007 Well the Warm Weather finally arrived and of
course it allowed me to continue work in the workshop. So
off i went having spent the winter getting 'Stir Crazy' to the
'Shop'. Everything has been planned, crosschecked
and checked again. The shell frame is finished at last.
It's 100% accurate and I'm very satisfied with the result.
 
 
So now the frame is finished, i am installing
all the panels and controls. I guess another month and
that will be completed. So we will be open for business
some time in the summer. All visitors will be most
welcome, so bring your Mum or your girlfriend :o)
December 6th 2007.
Got the roof made in the summer and then it was onto wiring,
audio, mounting the projectors etc. All finished by the end of
Sept. Here's the end product. Next spring I
want to install a floor, change the overhead and build the side
shelves.
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- The Cockpit Shell
