The first step in this process was to make an initial template of the throttle quadrant's cover from paper, which was done to ensure that all necessary slots were correctly positioned before any of the more complicated, time-consuming work was started.
Thin strips of MDF (approximately 3.2mm thick) were then cut and formed into the correct arc by wetting them with hot water and clamping them across the top edge of the side wall. Once they were damp they went soggy and could be formed into shape very easily. After this process, they were then left to dry and harden for several hours.
The notches in the sides, and the slot in the centre, ideally should be done after the correct shape has been formed as detailed above. If done before the hot wet forming, they tend to twist too much.
Below is an overall view of the unit once the document holders were fitted. There's actually an artificial bottom in the outer one because the smaller sheets kept disappearing out of sight!!!
This picture shows the clamps holding the rubber strips in place whilst the glue was drying.
Here's the almost completed throttle quadrant before the painting of the flap knob, reverser levers, and park brake lever.
And this is it with just the thrust reverser levers to paint.
Another view showing how the manual and approach charts sit in their pockets.
And the final photograph shows the completed throttle console fitted into place in the simulator. You might also notice the addition of two new pushbuttons, a red switch safety catch, and a black handle.Note: The rest of the centre console with the radios and audio systems is not yet complete, but is sitting in place so as to make things look a bit prettier!!!!