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Flight Simulator Toggle Switch Box Part 1

Something I have had on the back burner for quite a while now is a Generic Toggle Switch
Box that is as modular as possible.
As part of my effort making panels I took the opportunity to get this off the ground as it shares a few features.

Something I wanted to be able to offer is a Generic Toggle Switch Box for those flight simmers who don’t want full specific panels, but still be modular in a way.

I did a bit of thinking and thought I would do the initial concepts below.
Able to swap and change positions of switches where practical
Able to have a customisable top plate that can be swapped out showing various control names
Able to be Back lit.

What I have come up with utilising the design of what I am going to be using my own F18 panels. A box that is confirming to DZUS standards. It will accept a panel 146.05 wide, and be the Standard DZUS 9.525 hole spacing.

A quick mockup is below, the Box is MDF that when close to finalising I am deciding if I will vinyl wrap (carbon fibre perhaps) or enamel paint for a nice finish. The “rails” are 3mm acrylic that I will tap for an M4 bolt to secure the plates on.

The plates I am thinking to be as convertible as possible will only be 3 DZUS holes high (28.575mm) and will hold 4 toggles / rotaries etc.

This will be made up of a 3mm bottom plate to secure the toggles etc to, then a 3mm middle plate to space capture nut, then a 1.6mm Engraved ABS top to give a nice white surface.

One of the biggest problems, being generic is I had to come up with what I would engrave the top plates with by default, below are some of what I came up with that are relatively standard across most aircraft.

The plates with multiple will line up like below

Obviously being modular means there is a thin gap between each plate which I’m not sure I can eliminate, but if clients required and knew there exact layout I could do larger or a single plate to avoid that look.

The Benefit of this box being DZUS spaced is that my standard fighter plates can also be dropped in as well, and this is what I will be using to build my own personal simpit as I don’t have the space for a full cockpit build.

Some thoughts are to work out, how high do I do as a standard (currently 15 dzus holes high ~ 150mm) I think that’s a good starting point, but obviously can customise as much as required.

This box was a rough Mockup, I have a new one cut and waiting for the glue to Dry, once that’s done I’ll work out how I mount the LED strips for backlighting, and also work out how I will handle the cable wiring.

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