BL-001DESIGN / ENGINEERINGCOMPLETED
Initial Cockpit Design
From reference material to a project-specific 737-800 cockpit structure
Open Build Log →BUILD LOG
From Plans to Reality
The master chronological record of the project. Each stage has its own dedicated page for technical documentation, photographs and supporting evidence.
BL-002DESIGN / ENGINEERINGCOMPLETED
MIP Design, Pattern & Verification
Following the initial cockpit design, the Main Instrument Panel (MIP) was developed as a dedicated CAD assembly in Fusion 360. A full-scale physical pattern was then used as an intermediate verification stage before the final manufacturing order, allowing the design to be checked in practice before committing to the final 4 mm aluminium fabrication.
Open Build Log →BL-003FABRICATION / FINISHINGCOMPLETED
Aluminium MIP — Delivery, Inspection & Painting
The final MIP was received from fabrication in 4 mm aluminium, carefully inspected against the developed design and then prepared and painted before the installation phase.
Open Build Log →BL-004ASSEMBLY / INSTALLATIONCOMPLETED
MIP Panel & Instrument Installation
With the aluminium MIP painted and ready, the fabricated panels, instruments and associated controls were progressively installed and checked for fit, alignment and integration.
Open Build Log →BL-005CAD / 3D PRINTINGCOMPLETED
MIP Base Construction, Final Installation & FMC Unit
Display frames for the MIP screens were designed in 3D CAD.
Open Build Log →BL-0063D PRINTING / FINISHINGCOMPLETED
MIP Display Frame Finishing & Installation
The printed display frames were finished and installed into the MIP.
Open Build Log →BL-007STRUCTURE / FABRICATION / INSTALLATIONCOMPLETED
First Officer's Sidewall Structure — Fabrication & Installation
Fabrication and installation of the First Officer’s sidewall structure.
Open Build Log →BL-008STRUCTURECOMPLETED
Main Cockpit Base
The complete cockpit base was constructed as the foundation for the shell and lower structures.
Open Build Log →BL-009STRUCTURE / ASSEMBLYCOMPLETED
Lower Side Structures
The left and right lower side structures were fabricated, adjusted and installed into the cockpit base.
Open Build Log →BL-010STRUCTURE / FABRICATIONCOMPLETED
Left Window Frame & Liner
The left window frame and liner were built piece-by-piece. The liner uses MDF skins with a polyurethane foam core, joined with Gorilla Glue, before final installation.
Open Build Log →BL-011STRUCTURE / ASSEMBLYCOMPLETED
Windshield Construction & Installation
The windshield was constructed piece-by-piece using the same general approach as the left window frame. The construction photos are unfortunately lost; the installation is documented.
Open Build Log →BL-012FABRICATION / TEST FITCOMPLETED
Cockpit Glareshields, Windshield and Flight Deck Integration
Temporary fitting and alignment of the glareshield wings, No. 1 windshield, Captain-side cockpit window, EFIS and MCP.
Open Build Log →BL-013FABRICATION / STRUCTURECOMPLETED
Glareshield Final Shaping Preparation & MIP Low Panels
Preparation for the final glareshield shaping, initial MIP low-panel construction and upper glareshield construction before final finishing.
Open Build Log →BL-014ASSEMBLYCOMPLETED
MIP Low Panels — Fabrication, Finishing & Installation
The two MIP lower panels were fabricated as separate assemblies, finished and installed beneath the Main Instrument Panel with their controls and engraved labels.
Open Build Log →BL-015FABRICATION / ASSEMBLYCOMPLETED
MIP Low Panels — Construction & Installation
The lower MIP panels were fabricated, finished, fitted with controls and integrated into the MIP.
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