AVRPit Part 2 (modular design)

 
In the last AVRPit post, I "claimed" modular design.... but didn't do a good explanation nor demonstration on modular design. Here, in this post I will attempt to demonstrate what I meant by modular design.

In the next two screenshots, you will see that the basic frame design is very simple. It's built on top of a horizontal rectangular frame built with 1515 extrusion, sitting on two 6x6" wood posts with caster wheels mounted under the posts. Everything else are mounted on top of this frame, including a sliding car seat (not shown). In fact, the frame is built around the car seat. I chose a car seat that is narrow enough to fit inside an F-16 pit (most car seats are too wide), and then design the frame's width to fit the rail for the seat.

Up front mounted a plywood platform and two "gates" built with 1515 extrusion. The wooden platform is design for rudder pedals, so the rear half is covered with thin aluminum sheet for sliding of the the pilot's heels. It's really way oversized, but why not. I could always put the whole computer there. The two gates are designed to sit under your table, and to be used to mount all kind of stuff, like your front panel, driving wheels, yoke, etc. So, you can swap them out for different games/simulators. You will see this in pictures shown later.

The next picture shows you the real thing configured for playin regular games... like Arc Raider. The keyboard/mouse are sitting on a Mahogany board, which in turns sits on two solid OD=1" aluminum rods that I can pull in and out to fit where I like them. The two rods were mounted on the two 1515 frames using 4x 3D printed brackets (lockable). So, I sit in, adjust the seat position, and then adjust the keyboard/mouse tray position by pulling the two rods. Alway perfect at there I like them.

When I am done playing, I just push the keyboard/mouse tray under the table, and push the rods in, slide the chair back for easy exit.

Now you see the two rods are pushed in, and an F-16 front panel with HUD/ICP mounted up front (still need to do MFDs, and hood, etc.). In the back are a bunch of 3D printed brackets and spacers to make sure the angle of the board is exactly 10 degree every time I mount it.

Now you see the left hand side panel is removed, with just 4x thumb screws.

Also, note the right most of the frame has one additional 1010 extrusion running from the rear to the front. This is a permanent mount, not designed to be removed like the side panel frames. You can also see there is a black wire channel mounted on it. These are for running permanent wires. For instance, the main AC power extension under the seat (mounted on the side of the 6x6" wood post), and USB extension for two side panels run through this wire channel. Basically, any wires that go with the seat run here. There is another one of this on the left hand side.

As you can see, I chose not to mount the monitor on the frame, but decided to put the 43" 4K gaming monitor on a table, but put the front of the frame under the table. This let me save on the structural "beefiness" of the frame. In fact, my two front "gate" like frames are quite shaky. I didn't even bother to cross brace them. The good thing about this decision is that I get to easily change the position of the 43" monitor without worrying about dropping the darn expensive monitor, whether cantilever this damned thing is a good idea.

As you can see... all the positions of everything is adjustable.... so later on I can adjust them to fit what's in VR.

Now you see 3 side panel modular frames.

In the middle is the F-16 left panel module (you are seeing the bottom of it). It's a self-contained module with its own AC power surge arrest and extension, power supply, and an USB hub. This way, there are only two things to plug in when swapping the module in -- one AC power plug and one USB connection to the hub.

On the right hand side, that's for the Thurstmaster A-10 throttle quadrant, and a TM TCA Boeing throttle, for flying AH-64 in DCS, or Elite Dangerous. When flying Elite Dangerous, I would put a driving wheel front panel on, replacing the F-16 front panel.

On the left is an empty frame, with some 3D printed wire brackets mounted.

A modular panel frame is simply made with 2x 1010 extrusion, 2x aluminum plates, and two 3D printed end brackets (the black one).

The 3D printed bracket plugs into the end of the 1010 extrusion to fix the distance to be exactly 108mm center to center (TM Warthog's weird screw hole dimension... don't ask me why). This is because, even though I use an XTool MetalFab 1,200 watt fiber laser to cut that aluminum bracket precisely, there is just too much slob between the extrusion slot and screws. So, the two 3D printed end brackets fix the center to center distance to be exactly 108mm for other 3D printed parts to fit, for instance, the brackets to mount the AC power, USB hub, and power supply. Of course, these brackets are, again, also 3D printed.

The aluminum brackets are there for the strength and rigidity, and the 3D printed end bracket is there for accurate center-to-center dimension. Once you have all the parts printed, cut, the assembly of the frame takes only a few minutes.

Each of these frames are fixed to the "panel rails" with 4x 3D printed brackets and 4x thumb screws, nothing else.

So, as you can see, 3D printed parts have become the main glue to put all this stuff together, where traditionally, a lot of the parts would have been made with CNC milling, or other means. I still use those methods when needed, but 3D printed parts have become so substantial that I rarely turn on my CNC mill.