Community Event / Creation Attempting to create replica Pilots chair sim pod

[WhiteShadow]

Creating scale replica in-game Pilots chair to then create full scale gaming rig.

Hi all,

After reading through the entire thread of ThereIs0nly0ne's C-Pod link here as well as his R-Pod Mk II project here, and, while looking for images of the seat in game, stumblling accros Eewec's thread here, I have been inspired to make an as-close-as-possible replica pilot's chair to replace my current office-chair-with-hota-bolted-on-with-MDF rig that, even though comfortable and functional, just isn't quite what I picture myself sitting in while fighting Python's round the rings of a gas giant, or plodding along the space lanes trawling goods (with my truckers hat on of course).

I'd be looking to try and make it as identical as possible, and if possible, all working parts (chair elavation; extending foot rest; deployable/retractable throttle/yoke, lights, etc), I know it sounds like an ambitious project, but like a challenge, and I'm going to be curios as to how I will work out a way to achieve all of this!

Currently my setup looks like this:



But aim to end up with this:



I've drawn a side profile of the chair, in the hope that I might be able to use a CAD software to try and recreate a 3D model of it, then use that for reference while making the full size version:



Right, off to see if I can work out how to use Sketchup.....

 

[WhiteShadow]

Right, I now know that I can't get on with CAD packages... Id rather do it the way I normally attempt any big project like this... make a scale model, so I can play with angles, lengths, widths, ect, then when happy, measure all the panels, and scale it up into real world measurements... this way I get to do 2 things:

1: I got to get all the measurements as exact as I can from viewing the object, so I don't waste material when I come round to build it.

and

2: I get to use most of the scrap material I already have in my shed, that my wife keeps asking me to get rid of, but I keep saying that it'll come in useful one day!!

These are the reference images I'll be using.. If anyone has any better ones, please post here, I could do with as many angles as I can get if I'm going to replicate this as exact as possible!! (some of these images have been taken from other posts while searching the net, so a big thank you to everyone that have managed to get these brilliant images, and that I reproduce here.)



I'm planning to make a 2.5:1 scale model, as this should be small enough to reproduce on a workbench, but still be large enough to get precise measurements of the panels when scaling up to 1:1

Right - off to the shed to go and make stuff!!

 

[Enride]

As with everything high fidelity, youll have a handful with this mate!
Good luck and keep us posted, ill be checking in regularity!

 

[WhiteShadow]

A full day making the basic inner frame of the chair from bits of scrap MDF has been quite fruitful!

Using the side elevation plan, main sides measured and cut using 10mm MDF:



Then, again using the side elevation initially, as well frontal screenshots and a little bit of research for widths of racing bucket seats, the base and back are measured and cut. Batons are screwed to the back rest to support the side panels:



Side panels attached:



Now the upper side panels are measured and cut:



And attached to the backrest:



it's definitely getting the right shape!

The upper panels required a but of sanding once attached, but I was expecting this when you're playing with angles like this!

Everything will be screwed together as much as I can until the main design build is finished. This will allow me to then disassemble all the parts to take measurements and put full scale plans into place.

Right... now to start on the centre console cutout at the front of the seat!

 

[WhiteShadow]

You may have noted in my previous post that I planned to only screw bits together, so I could measure the component panels easier once complete... well, I've come across my first part I had to glue!

The front console cutout at the front of the chair started up as 3 sections, then ended up being made of 5 sections after noticing the slight arcing at the back.. in the full size version, I should be able to join these with screw in plates, but for it's smaller cousin, I've had to revert to good old PVA:

The Original flat sided version:


The I noticed this:


Which made me change it to this:



It is still easy enough to measure the individual panels this is made of from the outside of the piece, as the chamfer that makes the angles are all inside.

I won't round off the arc at the back and bevel the top until the final measurements are taken... but I have decided that I will complete the scale model, as I can also use it to test for filling and sanding between panels, priming and paint job finishes, as well as upholstery and electronics!!

Here I have removed the gap for the centre console (which can also be seen in the reference image above)



Now onto the front panels that sit directly under the pilots legs, these need to be shaped, I've done my best as per the reference image here:



Seeing as these were so small, my idea of using the jigsaw went out of the window, so I drilled holes around the perimeter of the shape, broke out the waste, then finished up with a sanding wheel on my rotary tool:



These then were attached to the main frame with wooden batons:



The last part I ended up doing today was to measure and cut the base struts and boards for the seat base and lumbar support, these will help shape the foam that will be used to upholster the seat:



Going to leave it here for today, I've spent pretty much all day in the shed.. I'd best go and make amends with the wife!!

 

[Enride]

Sickly impressive work!
Just as TIOO you too show excellent craftmanship and i would guess this is not the first time you do work like this?
I envy this skill and knowhow!

Looking forward to progress!

 

[WhiteShadow]

Ok, this is the final, FINAL post for the evening!!

After bringing the chair into the house, and after typing up today's progress, I realised I had some foam left over from another project, so I thought I'd do a little mock up of the main foam shapes that would be placed to get more of an idea as to the seat shape... doesn't look too bad!!:

 

[WhiteShadow]

Thanks Enride, that means a lot!!

I have done a bit of woodwork before, and have always made stuff since I was little (I blame Lego and Meccano!) - I think this will be one of the most ambitions projects I've attempted though... My last project was creating a tabletop PC for my wife for Christmas last year.. She got me to make it in a wooden chest!!

Well, this project will definitely be a learning curve.. I'll be quite happy to share all the dimensions once made, plus I'll be quite happy share the techniques I'll end up using as I work through the project!! If you ever devide to make something similar (or the same) I'll be quite happy to give advice where I can!

 

[Jypson]

Oooooh, looking pretty good! Can't wait to see how this comes along!

 

[Battlegrade]

Subscribed!

 

[WhiteShadow]

Just ordered a couple of sample swatches of leatherette for the seat cover. You can't really tell what grey is grey and if it's grey, or grey enough, so I've got a couple of samples coming:

 

[Cataclysm72]

Kudos and Rep for you, commander!

 

[WhiteShadow]

Well, It's been a little over a week, and I've been a bit quiet or a very good reason... Trying to do upholstery, from scratch, when you've never done it before is.... lets call it tricky... Tricky is a good word for it!!

But I prevailed, and stuck to it, and here is the result so far:

Here is what the foam backing looks like now after a bit of re-modelling to try and make it more bucket-seat shaped:



It looks a bit bitty, but it is still a work in progress, and will be covered with a thin layer of foam to smooth out any seams and angles more when it's ready to have the cover put on proper.

Next is initial shaping of the separate main sections - I will be making the centre insert section on the main back piece further down the line, as I'm guessing it's going to be a little fiddly:




As you can see, I've only created one side of the pattern, as these can be reversed and replicated to make it whole.

Replacing the centre pattern piece with leatherette (I've only got black at present as the swatches hadn't turned up by this point!)



Then the shoulder pieces, firstly tacked, then stitched:



Then a single side panel, to get the shape right:



This was then mirrored to create the other panel. This was stitched together and here is the final pattern, just tucked in between the foam and the frame:



Next is to give it a foam backing, and then fit it firmly to see if it stretches correctly... oh, and also to replace the centre panel, as the charcoal leatherette turned up the day after I took these!!

More to come!!

 

[Cataclysm72]

Car sets aren't that difficult really. I've reupholstered my DeLorean car seats (with store-bought seat covers), but it basically comes down to pulling the leather down from the back using springs or wires. So there's this metal frame, a bunch of springs/foam/cushioning and then the leather. The leather is tightened against the frame. This makes the nice buck seat seams.

 

[Sams]

I see your poor, poor cat has to suffer sitting in that terrible folding chair while s/he waits for you to build his/her new, more comfy chair

 

[WhiteShadow]

I must admit, it'd be interesting to see him try and sit in it once it's done.... CMDR Figaro reporting for duty sir!!!!

 

[WhiteShadow]

Well, After a short break due to friends birthdays, I'm back to the build, so here's what's been happening over the last couple of days:

I've put the upholstery aside for the time being, as I can't finalise it until I know how the outer casing for the chair will attach to the subframe, so I've started on this. Here is the initial draw and cut for the lower base sections that will hold the throttle and yoke controls;



Then with the stow-away section cut out:



Measured up, then cut and glued the side sections for these:





Now for the start of the fiddly bit... Measuring and glueing the inner frame for the stowable units:





I left the parts near the top free as there will be a spindle being inserted in here to anchor the arms, and trying to drill holes in line when this would be in place would prove impossible, so will make these parts later, then insert them as one unit with the spindle.

Final dry, then test fit:





Now onto marking out where the "greebles" will be on the panels. I intend to route out a 1mm groove to show the appearance of separate sections, but keep it as a whole unit... I'm sure there will be reinforcement behind these sections when the time comes!



I have decided that when it does come to fitting time, I will attach these using 3mm socket bolts. Every spot where there is supposed to be a bolt, I'll attach it with one. Just ordered them online, and should be here by the end of the week!!

Final fit before starting the upper section of the outer casing:



The upper section was quite fiddly, and unfortunately, silly me didn't take any pictures of the assembly process, but here are the sections assembled, and glue drying. I've strapped them to the rest of the sections so they don't warp at all during drying:



And finally, this morning before work, the masking tape is removed, and CMDR Figaro is now eyeing up his new command chair!!



That's all for now.. will carry on work this evening and bring you the next progress update!!

 

[Cataclysm72]

Nice! This will look so awesome when it is done. Count on me on following your build.==

 

[WhiteShadow]

Aha!! The post arrived at work with these goodies for me...

Twin axis XBox Thumbstick


And the bolts have arrib


Just waiting for these sockets to arrive now!!

 

[Cataclysm72]

Aha!! The post arrived at work with these goodies for me...

Twin axis XBox Thumbstick
View attachment 77371

I hope you didn't pay more than $1.29 for it!!

http://www.ebay.com/itm/1x-3D-Joyst...243960?hash=item463bd0b3b8:g:WuUAAOSwpDdVbVDo