Making Flight Sim Panels with my eBay Laser

[@hxhdfjifzirstc894]

This is only the second video of this project that I've seen, and I didn't realize it was all made from scratch. You must be quite proud of all the craftsmanship involved.

[@davewasthere]

Ex avionics engineer here. And yeah, that looks seriously good. Really respect the effort you've put into it. Well done!

[@jpr0729]

324k views, this video is still one of the best references on the internet for how to make these, fantastic job.

[@un65tube]

Wow - this video brings the possibilities using a K40 laser to a next level! Perfect. Thank you and greetings from Germany!

[@richpayton7162]

I had to repair or replace these panels when I was in the U.S. Navy. Back in 1973 a panel like you made here would cost at least $ 1K. They were certified flight equipment though. $100 for the part, $900 for the cert. Yours look great.

[@rallywagon261]

Well. 100 for the part, 100 for the cert... 800 for the gov contract upcharge... I used to be a mechanic in the Army (thank you for your service btw) and was regularly blown away by the upcharge on common parts.

[@TheRealYashNotFake]

I own some 1980s helicopter lightplates, old enough to have those Glar-ban instrument panel post lights and the backlight lightbulbs that can be unscrewed from the panel itself. What technology did manufacturers use to actually carve the black paint off and reveal the white lettering itself? Did laser engraving even exist back then or was it hand-operated with a stencil?

[@gracebyseven]

Nice mate. Almost exactly how I do mine. Just a tip, apply a little Bondo filler to the edges and sand down a bit to eliminate the seam where the parts meet. Another way around this is by actually welding the layers together first and then cutting as the heat from the laser will make the edges look seamless. Keep up the good work!

[@Sly_Wolf_1]

Really don't know why I watched this other than nosey curiosity.... But wow totally blown away with the quality of your project. Thanks for posting 👍

[@undercrackers56]

I am envious that you have space to do this stuff. Here in Blighty we live in sheds and if lucky enough to have a garage then it is only big enough to park a small lawnmower. I applaud you saving material at 4:40.

[@iankirwan8156]

As others have said, this is simply fantastic. Your skills and vision are inspiring. Thank you so much for taking the time to share all this with the rest of us and I'm already looking forward to learning more. Keep up the excellent work

[@stijnwenselaar1268]

Bruh. So nice and good looking. You made me wanna buy a laser engraver.

[@howardgreenwood]

Finally found a good channel for this. Keep up the good work. Im making a KSP control panel.

[@terryandreson3914]

I love sim racing but your DIY projects are so educational that I use them to make sim racing gauges. Nice job mate.

[@StreetComp]

You have a talent for making stuff (including how to videos) and could make and sell panels, etc and probably make decent cash as simulators of all sorts are just gonna get more popular and most people don’t have skills/patience/gear

[@reginaldcrudstump383]

The panel looks superb, thanks for showing us your technique.

[@DeltaBravoProductions]

OMG! YOU ARE THE VIDEO IVE BEEN WAITING FOR! nice job my friend!

[@captainboing]

probably the best rear-illuminated panel method I have seen. Excellent work! I used your conformal coating idea on the wiring for safety on exposed hi-voltage on my own boards. Cheers

[@finnigan16]

Insane quality! It looks perfect. I'm curious about the modifications you've made to the laser engraver, do you have a video or post detailing that?

[@claudehebert3131]

I second the motion! Please upload a dedicated video about your laser cutter, along with the mods you've done.

[@GaryMcKinnonUFO]

If you search for k40 laser cutter, youtube is full of detailed mod videos, there's also many blogs on the net about it.

[@redlioness6627]

I'm glad you said Zed table as I couldn't tell if you meant C or Zee when you mentioned it earlier, Zed is less confusing as no other letter has that same sound unlike B, C, D, P, T, V and for septics (septic tank = yank) Z, we can discount B, P and V, but pronunciation can bleed when pronouncing C, D, T and Z if someone uses American pronunication of Zed.

[@adamthompson8432]

What education do you have? This is absolutely incredible! The man even upgraded the Chinese machine?!?! What a legend. Talk about a super Genius brain!! My lord I wish I was brilliant at one thing in this life and you’re brilliant at everything!!! Can we be best friends?? Lol. I’m jealous!

[@velizarzdravkov6686]

Not exlend ... Magnificent! This quality of work is rematkable!

[@nagualdesign]

I've always thought it would be cool to have a custom-made control panel above the windscreen in a campervan, like an airplane cockpit with buttons and gauges for all the extra electronics. Now I know who to ask! 😎

[@markmaker2488]

Great job mate, super professional finish 👍

[@h4z4rd42]

Funny, last year we made a complete cockpit for a C5 and for a KC-10, for Terminator, I used almost the same method. Hint: you don't need to copy-paste-save as from a new tab, you can export selected object to dxf from the very same page you used for drawing directly.

[@Ferocious_Imbecile]

I am so impressed. When Stanley Kubrick made Dr. STrangelove it took the wealth and craftsmanship of a big movie studio to simulate the controls of a B52 bomber. You've equalled what they did back in 1960. Amazing.

[@mobayguy]

Amazing work - Excellent Craftsmanship! You've inspired me. When I retire, I resolve to build a SIM Cockpit of my very own F18 Super Hornet ! -Cheers

[@fahndraco526]

I found that one of the most informative video's on KZbin... Nice clear and easy to understand what you were doing at each stage... And now i am even more jealous of your A-10 Warthog cockpit and how you have built it, i just wish i had the know how and cash to spare to build something like this...

[@ericgriffinthefirst]

Awesome... I wish my ford truck and my mother in-laws car gauges ,air conditioner,etc Gauges switches were done like that.instead the lettering explaining what each button does is worn off.so when I use her car or try to use any button even the backseat front seat locks,seat directions, ect. I have to guess mostly .its very aggravating,the buttons aren't arranged intuitively either,and look the same.her car is only 2years old.Buick.it takes more thought and time.but its not only good to look at,but has a absolute purpose... In an air plain,you don't want to guess what buttons to push because of saving a dollar or two or more. Good work,very nice panel.

[@georgelza]

... @ 03:00 you mention/show the acrylic... that front layer, that all solid white ? trying to see in my mind how that allows light through with the front sprayed black and then lettering lazer'd out/off the paint. Question, @10:20 you do the drilling into the opaque layer... do you go all the way through it ? is yes... then sort of implies you touching the white layer. guessing my OCD tells me to rather do it on a drill press where the depth can be controlled.

[@petegledhill1256]

Any chance of doing a video on how you upgraded your k40

[@aaronjones4529]

Yes, this video was amazing, so now of course I (and Im sure, many others) want a cheap engraver and instructions on how to DIY improve it... PS. Your entire setup is epic!

[@LTVoyager]

It seemed as though the LED locations were still quite visible in the engraved letters, especially at higher brightness. If the LEDs were instead spaced around the perimeter, would there be enough light to still see the letters? It seems as though that would be much more uniform, but maybe it would not be bright enough.

[@Leadnap]

You can use rubber cement as a masking agent in the dial recess instead of tape - the liquid form will ensure no seeping of the spray paint at the edges of the mask. I know since the dial went over it wasn't a big deal, but IF it was this would allow that precision. Likewise, it can be much faster than trying to get the tape to conform.

[@StrongFreeLovin]

The Warthog Project, the type of guy to construct a plane to get himself a simulation of a real thing.

[@TheSilmarillian]

Best 17 or so minutes I have seen on UTube in some time tk for the upload hello from Australia

[@flybobbie1449]

Knocks my MDF flight panels into the shade. Inspiring video.

[@sorryeh7]

This is an awesome video! I am looking forward to a video on how you make your custom gauges.

[@hamiltonpianos]

Excellent work! What is the vinyl you’re using at 15:53? Is it a regular car wrapping vinyl that’s just been heated till it melts?

[@maartenvd84]

I was wondering the same thing...

[@schuur10]

After a year since you,ve uploaded this one i see this and it has some potentional for " How do they do it" ! It was fun to see how you make these "Important" instruments.

[@PWingert1966]

There is a video on here on how Boeing does side lighting for its gauges as well. the technique is quite similar.

[@blaster-zy7xx]

Yes, way cool. I do model making myself and it is great to see somone being very clever with homemade tools to create something so real looking and functional. I still have a hundred other questions how things were made, guess I need to subscribe.

[@Ryan_1988]

one of the most satisfying vids ive seen, great job. New sub and like.

[@thewarthogproject]

Thanks!

[@liveriesfsx9352]

@@thewarthogproject Hi mate , I watched few videos about your project and it's really impressive. I'm a newcomer to the subject and after making first simple panel with ~30 switches and buttons I'm working on the more sophisticated one, with backlighting, displays, etc. That's why I have few quick questions, also looking for advices. I appreciate if you could help me. How powerful power supply u used? I'm playing around with the LEDs in Tinkercad now to see how bright they can still be when connected multiple of them to several teensy/andruino boards but it seems with few dozens of them (in one of the panels with 120cm of width and ~20cm of heigh) it will be better to connect them separately to 12V power supply. They get too dimmed when using 5V, even with few circuts with separate 5v sources. I also consider to use 5050 led strip (30leds/m, 12V) cut in several pieces since I got >10m of it lying down in the cabinet. The middle plexi sheet - what transparency % would you recommend? Would it be not better to use also opal sheet for front panel? Tho I didn't have any of them in front of me, I though the solid one won't allow the light to go through. Cheers Mark

[@liveriesfsx9352]

Ooh one more question. What font size you use for engraving text?

[@hamiltonpianos]

@@thewarthogproject Any chance you could let us know what type of vinyl you're using at 15:58? Would love to see the method too if possible! :)

[@MrAnimal1971]

your commitment to detail is awe inspiring. keep the videos coming, Im getting so many ideas.

[@ibrahimbayri7290]

Well done mate, great job! Some tips like how to position the panel on the laser for etching is gold. Thank you

[@keirfarnum6811]

That’s really impressive. Nice work. Green with envy!

[@Stefan_Van_pellicom]

16:20 That’s cool ! Is that a special vinyl ? Do you have a video showing this process ?

[@BorisSpark]

If you sand the led it will spread light even better and not need to drill anything which makes it less likely to chip or crack anything.

[@fer_fdi]

Amazing work! Spectacular!!!!!!! What's the material you use to cover LEDs and cables? It is a melting paper? Can you give us a reference to find it please?

[@SpinStar1956]

Hi there -- Big Thumbs Up on your nice panel making. Did you ever make the video on making the gauges? In this gauge I noticed that you have watch-like concentric needles/hands and was wondering how you implemented the hand mechanics. I would sure love to see your gauge making video as I want to make some gauges/meters for my own use. Anyway, really awesome work and attention to detail -- Thanks!

[@SpinStar1956]

Super video; super project. Sure would like to see a video on the actual gauges. Have an application that has to have a custom gauge that I can't purchase. Will you be doing one sometime?

[@v8dave517]

Good job mate, great video and well presented. I learnt alot of tricks in such a short time. Just about to route through your other videos please keep them coming

[@darrenb3214]

Not only does it look quality, but these videos are also quite therapeutic lol. Great work. Would love to have the room for your set up.

[@StevenCookFX]

Another thought. Since the laser can cut light metals. you could get some light copper sheet and make a circuit board for your electronics

[@greyjohnson4124]

sadly these co2 lasers can barley even mark most metals and you need a cnc to do work like that unless you spray paint the board first and laser away all but trace location

[@mtbiker8]

Thanks for the excellent tutorial. I learned some great tips for my K40. BTW, that's quite some control panel on your laser.

[@garystump1776]

hey that was BOLD indeed I have never had the time. I am ready now lets get at it. tkank you

[@flymario8046]

Love the way you built this unit. The vinyl you covered the wiring and led's with on the back is very interesting to me because of my halloween projects. What is the actual material/product you use for that? Never seen it before. thanks!

[@jensvanhoof]

I'm also interested in knowing what the name of that product is!

[@seanc6754]

Very satisfying watching that laser cut that big perfect circle lol

[@lsdave]

Amazing work. Everything done just right. Love the use of the vinyl to cover up the light bleed as well as insulate the wires.

[@roygreig2843]

This guy is awesome, shares everything, can't wait to start my hog

[@foghornmalone4971]

RK, would you mind making a video detailing the upgrades you made to your laser machine? I have the same one and would like to follow suit. Gratzie!

[@foghornmalone4971]

Thanks! I found your Laser Upgrades video. You da man!

[@trialnterror]

I’m a electrician on the hog this is cool!

[@MacheteBushcraftAustralia]

Mate I got to say, the huge nerd in me really like this project!!! Nice job buddy and thanks for sharing. Really tidy looking bit of kit. I have not taken the leap into getting a cnc laser...but it's not to far away.

[@panagiotiselsisi7752]

Great work always generates questions from "DIY" people like me. So 3 questions for you. 1 why don't you paint the panel before starting cutting and save the alignment trouble later? 2 why don't you sand the edges of the acrylic sandwich to make it smooth and more realistic? 3 what font are you using for lettering?

[@thewarthogproject]

1) Because the edges of the panel and inside the holes which had been cut would be white - so I'd have to mask up the engraved letters and repaint. 2) Because the area sanded would be white - so I'd have to mask up the engraved letters and repaint. 3) just google MS33558 - you will find it free and it's the same font used in the real jet.

[@Just-Ross]

Excellent work! Could you please give me the details of the vinyl used for the rear of the stack for heat shrinking/protection? Thanks very much :)

[@petrtos]

I am also interested in the vinyl sheet. I have never seen such insulation. Could you please share details what material it is?

[@Stoney3K]

Looks like it's regular self-adhesive vinyl sheet which is used for automotive wrapping. Search for 'vinyl wrap' and you will find it.

[@jpotter2086]

Love my cutter. They're magic boxes. Great project!

[@RuneSmedstuen]

Am I the only one ripping my headset off at @01:00, having hopes to see a low-flying jet?!

[@h.cedric8157]

i thought i heard a C-5 Galaxy with TF39s

[@hxhdfjifzirstc894]

I paused the video to see if it was real. Once in a while, my house is under F-15 flight plans as they return to base.

[@jy4141]

Mate what a legend!! Home grown talent in Oz

[@calpilotmike]

Great stuff! I've been scheming on using my Glowforge to build both my avionics panel and individual instruments. Thanks for the insights and demonstration!

[@kerrycorbin2773]

Fantastic to watch..... I Would love to buy some finished panels if you end up selling some...

[@niklazz7037]

Amazing work, really detailed and very clean build!

[@maximolema]

Excelent project. Congrats. One question, why you used 3 layers and not just 2. I mean the first layer could be (your second layer) the one which difuses light, painted black on the front, and engraved.? Thanks if you can answer.

[@andrethib]

this is a great video, love your technique. at 10:30, you mention that you taped off the exposed middle layer switch surround -- if you hit the edges of the tape with a bit of clear (satin or matte) spray paint and let it dry before you spray the matte black, you can get perfect edges; this is called backmasking iirc. I understand that perfect edges are not critical in this situation, but I thought you might appreciate knowing about this trick

[@stevew9945]

excellent job, I used to repair panels like this on the Mirage and F1-11, yours are equivalent standard !

[@JJC2611]

I used to fix the RAAF F111s. I was a RadTech at 1 and 6 Sqn. If you were fixing Mirages then you were probably before my time.

[@stevew9945]

@@JJC2611 I was a radtech at 481 sqn and worked in radio workshops for a while then went to work in matra section on missiles for eight years, then after a while was a systech at 482 sqn in workshop 1. I spent the lat 14 years as a contractor doing avionics software testing at willytown. I gotta ask why are the lights green, they were red in the mirage and f111 so I bet they would be red in the a10. regards steve w

[@thekehoeshow..]

Thank you for doing what you do.

[@SSmith-fm9kg]

OK, at about 0:57, I had to stop the video because I thought a plane was about to hit the building I'm in. Thankfully, stopping the video stopped the sound... I enjoyed watching the process. The panel reminds me of when I was in the USAF in the early 1970s, I calibrated the radar and weapons control system on the F4-D Phantom II. The panels were illuminated with incandescent bulbs at the time, giving the identical backlit appearance.

[@PaulJosephdeWerk]

Do you have a video or web page on how you upgraded your K40?

[@MakerFarmNL]

Very nice back lights and clever to laser-engrave the paint.

[@constantinosschinas4503]

10:00 you could also laser engrave the led pocket, by cutting the part mirrored. great work, keep on.

[@wonderwulf]

This is really awesome! Beautiful method and results. Also, please be careful opening up that cutter when it is running! That CO2 laser has a stupid amount of optical power at wavelengths you cannot see. Major major eye hazard.

[@thewarthogproject]

Thanks! Safety glasses always!

[@llejk]

Yes, I actually wondered about the clear image, and then... OMG the laser is running while the hatch is open, no safety switch ?! You know at some point someone will open it without thinking or knowing. Murphy’s law doesn’t have an exception for retinas.

[@r.a.monigold9789]

Clever use of materials. Nice work. Thanks for sharing...

[@andrewhardie8138]

Best thing ive seen yet, fairly new to your channel so catching up :)

[@Gylfi0]

it's awesome, but did you post a video on how to make every button, switch and knob do a working recognized input for the pc?

[@johnwehunt4305]

I case you don't know. Groovy Game Gear has GP-WIZ 40 switch usb boards that are really affordable. They also have many other interesting PCB boards.

[@hypersmudge1]

A fascinating process! Thanks for taking us through it!

[@gvrose1]

Very cool. Love that little laser cutter!

[@GateKommand]

Thanks for an interesting insight into LASER cutting mate!

[@Waffle4569]

Why does the panel at 13:55 turn white? Is the metal itself white underneath or something? I always assumed it was just painted.

[@a7i20ci7y]

The panel is white acrylic painted black. The laser is ablating the the paint and exposing the white acrylic underneath.

[@AcydDrop]

You're obviously hugely clever. I just wanted to mention that you don't need to spend a lot of money on special acrylic cement crap. The best thing to bond acrylic to itself permanently is acetone and it's a lot cheaper and does exactly the same thing. You may, or may not have to use slightly more or slightly less but the cost for a can of acetone is no doubt much less expensive. Just a piece of useful (or useless?) advice.

[@Dabaiko]

That is amazing! What adhesive vinyl are you using? I didn't know you could use it as heat shrink. Does it last or does it peel off with time? Asking because I see the video is five years old now.

[@ovalwingnut]

The airforce just called, theywant 6,000 of those panels by the end of the month, stat! Xlint job. Color me VERY IMPRESSED

[@BillySugger1965]

Excellent work. Looking forward to the gauge video you mentioned...

[@muzzaball]

Incredible..... and realistic! Well done.

[@wojciechbury8059]

Nice way of using cheapest Chinese laser out there that's not totally worthless. One thing though, when you're engraving use the other axis, it's way lighter, you can get much faster speeds, also, you're not using up your linear bearing and bar that it rides on which are probably way harder/pricier to replace than those 4 plastic rollers on a gantry, maybe even gantry itself.

[@sej84]

laser cutter is a budget... but the result wow! I'll have to negotiate with madam... :) As everybody asked before in the comment, It should be really great to show us you've upgraded your laser (if it's not already done somewhere else and if it not only an option to get better results). PS : otherwise I have a reflection to do that with a milling CNC but as I'm a completely begginner I suppose the result will be someway really bad to engrave acrylic... (If somebody have an experience with that it should be great...)

[@antonwinter630]

very cool. great result on the panel

[@cerberes]

What a great technique. excellent job!

[@Scottforyoutube]

any chance you could tell me what the heat shrink vinyl product you use is? I can't seem to find it.

[@adamarzo559]

You could try heat transfer vinyl. It's meant for shirts but looks similar to what he's using. Going to try some myself.

[@Chapter3Fan]

Awesome ... when can I order some Fokker 50 panels I'm missing ?? :,-)

[@henrikwerder]

Do you do the knobs to? If so I would like to see a video on that. 🙂

[@craig221081]

Just started watching this and I find it amazing. Where is the video on how the actual gauge is made??

[@thewarthogproject]

Havent made one yet. I hope to soon, just need an excuse to rip one of them out.

[@legrompf]

Absolutely Brilliant ! can you explain how you made the knob which is so cool ?

[@joetylerdale]

Nice Vid, I been using CorelDraw for many years. It includes PhotoPaint too (both Adobe alternatives), and will never go back to the costly Adobe system.

[@hxhdfjifzirstc894]

I remember using CorelDraw back in the early 90s. I didn't know it was still around.

[@flybobbie1449]

I still have coral draw. It was a free copy from Currys here I the UK back in early 2000's. Still the most useful software disc i don't want to lose.

[@Reginaldesq]

Good video. For the future it would be good to get your terminology right. For example: you were saying opaque when you should have said translucent. This might help you. Opaque = no light will pass through. Translucent = light will pass but no clear shapes visible (diffused). Transparent = light will pass through and shapes are clearly visible.

[@lm198]

Excellent Work. Thanks for sharing. Amazing work