Cessna 172 Mark III Build Guide
Cessna 172 Mark III Build Guide
C172
DIY FLIGHT SIMULATOR
HOW IT
The goal was simple: create a low-cost
but effective flight simulator. However,
this goal is much easier said than done.
Modern flight simulator hardware can
BEGAN -
cost hundreds and often thousands of
dollars which would be far too expensive
for this project. Because of this, nearly
the entire sim would need to be built
THE C172
from scratch. The sim began its life with
a complex CAD model that was iterated
multiple times with input from
structural engineers and other industry
specialists. After nearly 6 months of
A Truly Amazing Aircraft engineering, the design was complete,
and with the creation of a Bill Of
Materials, the sim was ready for
construction.
ASSEMBLY
CONSTRUCTION
FROM THE GROUND
UP
Impressive new flight The Cessna 172 home cockpit took off on its maiden flight
a mere 30 days after beginning construction.
simulator takes off on Construction of the prototype began in June of 2020 and
was completed just one month later. The assembly of the
its maiden flight simulator started with the creation of the main PVC pipe
skeleton. Following verification of correct structure
assembly, main panels were cut to size and installed.
These steps completed the basic simulator structure and
By Ben Lambertson
Photo courtesy of Ace Simulations allowed the build process to move on to the most
important part, the electronics. Every part of the 1984
C172 instrument panel has been recreated from scratch.
The panel is created using foamboard with multiple
microcontrollers connected to the main PC. Finally, with
all parts built and assembled it was time to fly!
TIME TO FLY!!!
The Ace Simulations C172P finally took flight after a combined time of nearly two years
in development. Now, after nearly another full year of testing and improving, we are
ready to release full build plans for this incredible, low-cost, flight simulator. Whether
you are wanting to just have fun, or use this as a training tool we have got you covered.
00 - 02 Overview
05 Table of Contents
07 Engineering Drawing
08 - 02 Bill of Materials
C172 CREATED BY
ACE SIMULATIONS
Last Revised: July 07, 2022
B U I L D
15 Shell Assembly
16 - 17 Yoke Construction
19 Panel Prep
20 - 24 Panel Construction
25 Software Setup
35 Troubleshooting
Cessna 172 Mark III
Section Last Revised: 6/2/22 Part 1/3
Structure Assembly
Build Guide
SW Oriented
Isometric View
Section
I
Bill of Materials Section
2 3/4 In 3 in
8 3/4 In 3 Way Elbow
2 3/4 In 7 in
1 3/4 In 5 Way Tee
2 3/4 In 8 in
4 1/2 in 2 Way Elbow
2 3/4 In 12.5 in
6 3/4 In 21 in
Size/Number Part
2 3/4 In 22.5 in
* White Foam Board
1 3/4 In 27.5 in
x2 32 x 40 (in) Black Foam Board
5 3/4 In 39 in
10.5ft** Plywood Wood 2x4
1 3/4 In 49 in
21.5 x 42 (in) Plywood .sheet
x2 Sprocket
6 3/4 In 4 Way Elbow
1 SimStart.bat*
10 Switches
1 Arduino Leonardo
NOTE: Text in blue is
2 Usb Extensions
hyperlinked.
1 USB C to 2 HDMI adapter
(*) Software included in
1 Universal Serial Bus Hub
download
1 Power Bar
PVC Assembly Section
BUILD NOTE: A lettering system is used
throughout the build process. These letters
IV
reset back to A on each new step. Parts Needed:
1 Roof Assembly
x3 39in (A)
D x2 21in (B)
C
A x2 12.5in (C)
B
A x2 7in (D)
D
x1 4 Way
C
x2 2 Way Elbow
A
x3 3 Way Tee
B
x2 3 Way Elbow
C B x2 3 Way Tee
x4 3 Way Elbow
D
PVC Assembly Section
IV
3 Base Parts Needed:
x1 39in (A)
x2 21in (B)
B
x1 8in (C)
B
x2 3 Way Elbow
x1 3 Way Tee
A
x2 20.5in (B)
A C
x2 21in (C)
C x2 3 Way Tee
B
B
PVC Assembly Section
IV
6 Vertical Beams Parts Needed:
C x1 49in (A)
D
B C x1 39in (B)
Step 5
Assembly D x2 22.5in (C)
x2 3in (D)
A
x2 3 Way Tee
Install Side Structure from Step 5
It is recommended to drill
the hole in the PVC pipe
before installing the
Install Roof Assembly from Step 1 screw.
Support Table Assembly Section
V
1 Table Top Parts Needed:
B
Centered C
A
C
A x1 .5 x 21.5 x 42 (in)
x2 20in 2x4 B
B
Centered
C
x2 18in 2x4
Parts Needed:
2 Table Legs 3 Secure Wood
x2 25in 2x4 (A)
To attach the wood to the Table Top use
2-3 screws installed at even points along
the wood beam.
A
A -1.25- A
Space between A must be
1.25 in
Section III and IV Assembly Section
VI
VII
B
D
C
A
A
A
A
Parts Needed:
B
NOTE: When attaching the
A Foam Board to the PVC
pipe structure it is
recommended to use a
x4 20x30in x1 41.5x37in screw with a washer. This
will prevent the foamboard
from popping off the screw
over time.
C
D
x1 39x50in x1 43x50in
Yoke Construction Build x2 Section
6 inches
1 in
diameter of your bearing that is
Part A x2
3.5 inches
centered and 1 inch from the
top as depicted to the left.
Part B x2
1. 3.5 inches 3.5 inches
2. Assemble the Bearing box. (see figure
16.1) It is recommended to use wood glue
and wood screws to secure.
3. Install your bearings in the holes and
secure them with glue.
4. Install a PVC shaft to fit in the Inner
Diameter of the bearings you chose. On
the end of this, mount a 40-sized sprocket.
(Figure 16.1)
OR
Option 2 - Recommended
Use a pillow block bearing to secure the yoke shaft.
1. Cut a 2 ft long 3/4in PVC pipe
2. Slide the pipe into the bearing so that the bearing is 6 inches
3 in
from the end of the pipe (this may take some effort - some
material may need to be removed to get a 1in diameter) 3 in
3. Slide a sprocket on so it is 3 inches from the top and secure it.
4. Slide a second bearing on the end of the pipe so that a bearing
is on the end followed 6 inches later by a second bearing. (see
figure 16.2) Pillow
Bearings Sprocket
5. Secure the pipe in the bearings using glue
(Figure 16.2)
NOTE: Parts are not drawn to scale
Yoke Installation Section
VIII
1. Cut wood to match Part
--- 1.5 ft --- A
2. Screw the smaller
portion of the cabinet
glide to Part A with a 1-
inch clearance on each
(Figure 17.1) side (see figure 17.2)
3. Install the cabinet glides
20 inches on the support table
8 inches
1.
A mounted at the back of
1 in 1 in the support table (see
2. figure 17.1)
(Figure 17.2)
3. dddddddddddddddddddddddddddddddddddddd
4. Install the yoke mounts to part A so that the shafts are 18 inches
apart and centered.
5. Connect the sprockets with 40-size roller chain - Test the yoke
linkage as pitch and roll should now be linked correctly.
6. Attach potentiometers as shown in figure 29.2 here
COME BACK AFTER THE PANEL IS CUTOUT
1. Temporarily mount the panel as shown in figure 26.1 here
2. Cut out holes for both yoke shafts to pass through.
PROCEED BACK TO PANEL CONSTRUCTION HERE
If you experience any issues please contact support at [email protected]
Final Assembly
and Setup Guide
Prep For Electonics Section
I
To prep for electrical work drill a 2-
inch hole 2 inches to the left of the
center and 2 inches from the
bottom of the wood table. (See
picture below)
Center of Sim
-2in- 2in
-
2in
-
Cut a 40x15 inch foam board and install
Solder 2ft of wire to 9 switches and 5
it as displayed below. This will create a
buttons and the model 2120 connector
shelf for electronics to go in as well as
(See picture below)
provide a space for cable management.
NOTE: This does not need screws as the
table sides will hold it in place. Cut out
space for the legs as needed.
+ -
2ft of wire
NOTE: The model 2120 connector is not
polarity dependent. Wire the buttons in the
same manner
Panel Construction Section
1 Misc Panel II
7.25 inches 1. Cut panel to the specified size
2. Glue printout to front, folding
1.5 inches
5 ELT/Hobbs Meter
1. Cut panel to the specified size
II
2. Glue printout to front, folding excess around to the back
1 3/8 inches
Wire a circuit using a rocker switch, 9V Battery, and Hobbs
Meter then install the switch in the ELT. (see figure 21.1)
9V + -
Rocker Switch Hobbs
1.25 inches Battery +
- Meter
(Figure 21.1)
6 Engine Instruments
3.75 inches
3.75 inches A Servo
2.5 inches
B
1.5 inches
B x2 A Servo
B
1. Cut panels to the specified size (Figure 21.2)
2. Glue printout to the front of the larger cutout (A), folding excess around to the back
3. Cutout hole for servo needle to pass-through
4. Push the instrument needle through the hole and glue it into the servo arm
attachment
5. Glue Part B perpendicular to part A so that the servos rest on this shelf (see figure
21.2) - repeat for both levels of servos
6. Wire the servos to the Arduino Mega as shown here (Ensure wires are long enough
for the Mega to go below the engine instrument panel, 1 servo needs 2ft of wire)
1. Cut panels to the specified size
7 Annunciator Panel 2. Print the printout at 130% scale and cut
8 inches
1.25 inches
4 inches C x2 D x2
NOTE: Parts are not drawn to scale
2.
3.
Annunciator Panel Continued
4.
Section
5. Glue together parts C and D (see figure 22.1)
6. Glue part A to the assembly so that the
II
printout faces away from the assembly. (see C
figure 22.2) D D
7. Cut part A using the inside of part C and D
C
assembly. (see figure 22.3)
(Figure 22.1)
8. Wire a circuit as shown below (see figure 22.4)
9. Glue the lights to the center of A
part B
10. Glue part B to the A, C, and D assembly with
(Figure 22.2)
the lights facing toward the printout C
11. Install switch using the included nut A
D D
to hold in place
C
12. Tape the battery next to the switch
(Figure 22.3)
on the back of part A
x2 AA + Toggle Switch
- 3in - ----- 2in ----- - 1in - - 1in -
Battery
-
Small LED light (White)
(Figure 22.4)
See figure 22.5 for a completed panel
Light shines through printout with tissue
paper giving off the intended color
A
D C D
Switch Battery
B
----1in----
hole is 4 1/2in up
and 1 1/4in from
the right side C x2
A 2in
20in
(Hole is 1/2in)
4 3/4in
4 3/4in
6 1/4in
1. Cut out the panels with the specified dimensions making sure to
make 2 of part B
2. Create a 90 degree bend on the dashed line of Part A so that the
panel can follow the structure of Part B
3. Glue both Part C together
2 Assemble
1. Glue Parts A and B together to create the center
pedestal structure
2. Install a switch in the Fuel Shutoff cutout and
connect it to the Model 2120
3. Install a push button in the Fuel Selector cutout
and connect it to the Model 2120
4. Glue Assembled Part C to the push button
See Figure 24.1 for the completed pedestal (Figure 24.1)
NOTE: Parts are not drawn to scale
Software Section
1 Software V
1. Download and install all software located on the Bill of
Materials here.
2. Open the software folder included in your purchase
3. Read each README located in each folder and complete the
instructions included
4. Verify each application works as intended
2 Wiring Microcontrollers
Wire the Arduino Leonardo as shown by the project linked below
NOTE: DO NOT USE SOFTWARE IN THE PROJECT LINKED BELOW
https://www.circuito.io/static/reply/index.html?
solutionId=629105c53726d8003007ebda&solutionPath=storage.
circuito.io
NOTE: Add 2ft of wire connecting the potentiometers/buttons to the breadboard.
3 Microcontrollers
1. Download and install the Arduino IDE
2. Copy the joystick and controller folders to C:\Users\<your
username>\Documents\Arduino
3. Open the leonardocontroller.ino file and upload it to your
arduino leonardo. (Go here for help uploading)
3 Arduino Mega
1. Secure the Arduino Mega below the Engine instrument panel
using velcro
2. Plug the USB into a USB extension to be run to the main PC
4 RPM Gauge
1. Follow the tutorial linked here (This is not an Ace Simulation
creation)
2. Install the gauge in the bottom left cutout (see figure 26.1)
Panel Completion Section
5 Switch Panel VI
1. To install the Saitek switch panel simply slide the panel into the
foamboard cutout. It is a friction fit however you can reinforce it
if you find that necessary.
2. Run the USB to your USB hub
6 Hobbs Meter/ELT
1. Mount the Hobbs meter in the previously cutout hole
2. Secure the ELT using velcro allowing wires to pass through its
previously cut hole
3. Secure the battery to the rear of the instrument panel
7 Bezels
1. 3d Print 7 standard bezels and 2 bezels with the corner cut off
(these are located in your package download)
2. Mount the 2 bezels with removed corners in the instrument
locations with a button cutout
3. Mount the remainder of the bezels in the remaining instrument
cutouts.
NOTE: These are all friction fit, however, further attachment can be done as needed
9 Rasberry Pi Screen
1. Plug the HDMI and USB inputs into the screen
2. Run the HDMI cable down to the main USB hub area then on
the main PC
3. Run the USB power cable to a power bar
Panel Completion Section
10 Propwash Radio VI
1. Install the propwash simulations radio panel in the space
remaining between the autopilot and transponder
2. Run the cable down through the cable hole cut earlier and plug
into the USB hub
11 Instrument Display
1. Install your screen of choice behind the instrument panel
2. Route the power cable out to the main power bar
3. Route the Video cable to the main PC and connect both the
Rasberry Pi Display and Instrument screen to the USB C to
HDMI splitter
(Figure 29.2)
2.5 inches
1 3/4 in x 2 inches
OR 1/8 in
NOTE: This same method can be used for the pitch control on the yokes.
Yoke Roll can be connected directly to the rotation of the yoke
C x4 3 Way Tee
C
Door Assembly Section
(Figure 30.1)
Panel A
Panel B
(Figure 31.1)
Sim Completion Section
16 Glareshield VIII
1. Cut out foamboard to the size specified
2. Cut out 45in by 25in Faux Leather
3. Bend the Foamboard to allow it to sit on
41in
top of the panel
4. Glue the leather to the foamboard folding
excess around the sides
5. Mount this to the panel as needed
11in
17 Center Pedestal
1. Center the pedestal relative to the main panel - cut out space as
needed for the floor PVC bar to pass through the pedestal
2. Wire the trim wheel potentiometer into the Leonardo as shown
in the wiring diagram here
3. Plug the button and switch into the model 2120
18 Decals
1. Print out and glue the decals (found in the printouts folder of
your download) onto the sim panels - this is customizable so
configure to your preferences
19 Lights
1. Install puck lights in the ceiling of the sim using the included
adhesive
2. Attach RGB strip lights to the glareshield cutting the excess to
be wired elsewhere or run the lights somewhere else on the sim
Sim Completion Section
x2 2in (B)
A
x2 2 Way Elbow
B
A
x2 3 Way Tee
NOTE: THIS USES
1/2 inch PVC pipe
x1 1/2in to 3/4in
21 Visual System X
1. Mount your main display and window display on legs and rest
on the support table OR mount the screens to a wall and
position to your preference
22 Audio System
1. Mount a Sound bar directly behind the panel underneath the
glareshield and position a subwoofer in the corner of your sim
room OR use a different sound setup of your choice
23 Faux Leather
1. Cut out a 28in x 49in piece of Faux Leather and mount to panel
A (see figure 34.1)
2. Cut out a 28in x 31in piece of Faux Leather and mount to panel
B (see figure 34.1)
3. Cut out 2 28in x 9in pieces of Faux Leather and mount to panel
C (see figure 34.1)
(Figure 34.1)
B
C C A
Cessna 172 Mark III
Section Last Revised: 4/13/22 Part 3/3
Troubleshooting
Guide
Software Troubleshooting
1. Yoke/throttle is not responding Section
I
a. Check that Arduino Leonardo USB is plugged into USB hub and is
showing up in Windows Device Manager
b. Open Leonardo Controller Software in Arduino IDE and reupload
software
c. Open controller settings for the Arduino Leonardo and reset to default
d. Recalibrate controller
Sincerely,
Ben Lambertson
CEO OF ACE SIMULATIONS