A continuation of the throttle quadrant

This entry details the completion of the throttle quadrant ...

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!!!!

Early stages of the ATR72 Throttle Quadrant

From photos and other pieces of information I'd collected from a wide range of sources, and with some minor adaptations to suit both my abilities and the material available, here's how it all started life ...

The throttle and condition levers are made from some aluminium extrusions I found at our suppliers, and although the dimensions are not quite true to the real aircraft, they're close enough to be used in a simulator. Most of this stuff is hidden below the top cover at a later stage and is barely seen.


The flaps lever and the gust-lock lever are made from some stainless steel tube, which was found just laying around in the workshop - or rather, awaiting its purpose. There's an inner and outer tube, which (as the outer tube has the axle pin going through the bottom) allows the inner tube to slide in and out over a short distance. Seeing as there are no great stresses put on these parts however, they could just as easily have been made from aluminium. The flap knob was carved from a piece of scrap wood that I found lying about.


The park brake lever is a flat aluminium bar and there's a spring mounted on the axle which enables the lever to be moved sideways to clear the stops (a thin strip of plywood) for releasing the brake. The parking brake has a spring return when it's released.


Inside the condition levers is an aluminium bar, and attached to this is the pin that slips into the notches along the top arc of the quadrant. You will see that it protrudes out the other side slightly, which creates an attachment point for the spring return. The longer pin which you can see protruding (near the top of the photograph) is the actual release lever for the condition knob. The small cables are for Fire Warning lamps that one day will go in the head of the conditon knobs.

The brass pin in the flaps lever (which is a tight press-fit into the inner tube) slips into the notches along the top arc of the quadrant, and has a spring return on the other side in a similar manner to the condition lever.


This is a view of the mechanism behind the gust-lock lever, showing its return spring, throttle stop bar, and the arc in which its latching pin travels and locks into at each end.


The next photo is from the lower rear and shows the notches that the various levers slip into.You can also see the return spring for the throttle reversers. The row of three small nails was a temporary stop for the flap lever, which eventually had a small wooden block glued and nailed into place.


And this is it mounted inside the throttle box ...

As it stands today ...

This blog has been designed to show and record the progress of my home-built ATR72 flight simulator, from the first laying of its foundations through to its current state and shall be updated regularly as various improvements are made and additions fitted. Below are some recent photos to show how it looks at the moment.

Fully-operational AutoPilot, Radios, and Landing Gear Lever and Indicators ... Click here to see a short video of the landing gear in operation.

Fully-operational Throttle Quadrant ...

The partially-operational Overhead Panel ... Click here to view a short video of it actually working (as well as the throttle quadrant being used as per a typical engine start-up ) ...

And finally, an overall view of the cockpit as it currently stands today ...

Future updates will detail the flight simulator's construction stage by stage and the trials and tribulations thereof!