Instructions for making backlite panels.
When i started thinking about making my own cockpit, i came upon the backlite panel problem.
After searching the internet for helpfull information, i came to the conclusion that nobody found a solution to reproduce the panels as real as possible.
Then i started to work something out that would have the result that comes as close as possible.
Firsth the structure of the real panels.
The panels consist of a backplate covert with the frontplate.
The backplate is just a peace of metal which hold all the switches, led indications etc.
The front plate is for the visual part. It allows backlitening, adding the index etc.
The frontplate is put over the backplate and is fastened by just a couple of screws (or in some cases) gluid on the backplate.
The backplate is just a peace of metal with the size that is just a bit bigger then the front plate.
It holds all the switches ect.
If you plan making panels the way that is discribed here then you should follow the instructions.
First make shure that all the holes for the switches line up with the holes of the frontplate.
E.G. the backplate is a copy of the frontplate with the difference that the holes in the backplate are a bit smaller (they have to hold the switch), and that the outer size is a bit bigger (just one or two mm's)
Make shure that you make the attachment hole in the corners / sides.
Paint the backplate black (either paint or spray for a better finish).
The frontplate is a different story. You want backlite and a clear index on it.
So how did i do that. I came upon some tips for producing backlite but none of them where satisfied for me.
Although they gave me the solution for the way i am making them. So thanks for the people for putting there knowlidge on the web.
First of all, make sure you make a drawing of the panel you want to create, with the right size and lettering (index) on it.
Use the right size of fonts so that the lettering will be clear when the panel is finished.
Then make a print of it on a transparant using a lazer printer. Make shure u print in black/white otherwise the black wont illuminate the light.
Even more inportant make sure you print it in mirror, this will make shure that the print is on the backside of the transparant instead of the front (so you dont have to worry about scratching the paint of). If you use a good printer (go to a copy shop if you dont have one) the black finish is good enough to block the light).
If the light isnt blocking enough to your satisfaction you can spray the print with white paint.
For the panel itself i used plexiglass (8mm). Cut it to size of the printed panel (make shure you have left places out for the attachment screws for the backpanel). Finally glue the print on top of the plexiglass. (first glue and then cut the print to size to make sure that the sides are perfect).
Short note: you have to paint the sides of the plexiglass to prevent lightning coming out of the sides. (same for the holes that hold the switches).
Make shure that the holes for the switches are a bit bigger then the holes in the backplate (the backplate is holding the switches remember)
Making backlite possible i used some special LED's. (specially made for backlitning, the have 85 deg light fuse)
I drilled holes in the backplate (not all the way) where i wanted to have the lightning (about 15 for the landing gear panel) and wired them i series with each other.
For the wiring of the leds you have to make small canals in the back of the plate.
As you can see this side is still under construction.
In the near future i will add some pictures to make it more clear.
Biggles.
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