Overhead Section

747 – 400 / 8

Information and DIY construction guide

By Frederic RENQUET
Intro
Due to the lack of information available on the internet, I decided to compel this document to bundle
all of my personal research on this topic. In the second part of this document, you will also find how I
constructed my Boeing 747 overhead section. At regular intervals, I mention the modification I made
to the original Boeing design to fit my personal needs in my home cockpit. In the same line, I also
mention my own thoughts on improvements or on subjects which I will need to take a closer look to
if I will make an update on my overhead section. (This sections are marked in italic.)

To situate and orientate the reader of this document, I will already state that the simulator is P3D
driven for visuals and PSX driven for logics. The hardware components are linked to the pc’s by
means of OpenCockpit in-, output, master and expansion, servo and axis cards. To get from SIOC
variables to PSX, I am using the PSXSEECON scripts. The panels are not backlit, for now, as I don’t
require this momentary, but it is under consideration for a future update. However the panels are so
fabricated that they can easily be backlit. Besides the Korry replicas and the annunciators, all
hardware can easily be found on the internet with suppliers like Conrad, Distrilec, Allekabels,
Aliexpress, Banggoods, etc. The Korry replicas, annunciators, and many other items (like starter
knobs, fire handles, etc) are my own design and are printed with a 3d printer.

As my simulator is setup in a spare bedroom, and because of the double purpose of the room, the
overhead can be folded upwards, to conserve space in the room itself (especially because it is located
next to a doorway, and I don’t want anyone banging into my simulator 😉 ). My home simulator
originated as a fixed base B747 dual seating personal trainer, but due to lack of space I reduced the
MIP (FDS supplied) to a single seat trainer. Meaning, the F/O section of the MIP, glareshield and
hardware are left out. However are the overhead and pedestal sections are fully developed.

Due to the same reason, my cockpit does not have a shell (anymore) and the main visuals are
restricted to one screen only (mainly forward looking, but can be panned in all directions by a
hatswitch on the control column). I have the possibility to add a second screen on the main visuals,
but this would be only for entertaining purposes.

My own research took place over the last couple of years. Big helps hereby were the PSX manual,
PMDG manual, many pictures and hours of google (not always with the same level of result).

If there are any questions you would like to see answers, which are not contained or handled in this
document, feel free to pop the question to [email protected]. If your question is deriving from an
illustration, please mention the illustration number in your question.

At last, I want to thank all other builders for sharing their experiences and knowledges on various
websites and forums.

Thanks for reading,

Kind regards,

Frederic

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Index

Intro ......................................................................................................................................................... 2
Index ........................................................................................................................................................ 3
Overhead and panel information ............................................................................................................ 5
1. Overhead section ........................................................................................................................ 5
2. Overhead panels.......................................................................................................................... 7
3. Panel details ................................................................................................................................ 9
1.3.1. Cockpit light control panel .............................................................................................. 9
1.3.2. Hydraulic system control panel ..................................................................................... 10
1.3.3. Electric system control panel ........................................................................................ 11
1.3.4. IRS control panel............................................................................................................ 13
1.3.5. EEC panel ....................................................................................................................... 13
1.3.6. ELT control panel ........................................................................................................... 14
1.3.7. Landing/Runway light control panel ............................................................................. 14
1.3.8. Anti-Ice and Window Control panel .............................................................................. 15
1.3.9. Fuel pump control panel ............................................................................................... 16
1.3.10. Engine start and Fuel jettison control panel ................................................................. 17
1.3.11. Fire control panel .......................................................................................................... 18
1.3.12. Miscellaneous control panel ......................................................................................... 19
1.3.13. Navigation light control panel ....................................................................................... 20
1.3.14. Pneumatic pack control panel ....................................................................................... 21
1.3.15. Air handling and Temperature control panel ................................................................ 22
1.3.16. Pressure control panel................................................................................................... 23
1.3.17. Yaw Damper and Pax Oxygen control panel ................................................................. 24
1.3.18. Cargo Condition Air Flow control panel ........................................................................ 25
1.3.19. Headphone and mic boom panel .................................................................................. 25
Fabrication information / guidelines ..................................................................................................... 26
1. 3D printing / CNC ....................................................................................................................... 26
2. Base and subbase layer details.................................................................................................. 27
3. Painting and engraving .............................................................................................................. 29
4. Printed elements ....................................................................................................................... 29
4.1. Korry replicas ......................................................................................................................... 29
4.2. Annunciators ......................................................................................................................... 31
4.3. Starter switches ..................................................................................................................... 32

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 4.4. Fire handles ........................................................................................................................... 33
4.5. Outlet valve indicators .......................................................................................................... 35
4.6. Fire horn (replica) .................................................................................................................. 36
4.7. MAP light ............................................................................................................................... 37
4.8. Compass ................................................................................................................................ 38
Overhead box construction ................................................................................................................... 40
5.1. Panel box ............................................................................................................................... 40
5.2. Overhead box ........................................................................................................................ 43
5.3. Front section.......................................................................................................................... 49
LIST OF ILLUSTRATION ........................................................................................................................... 50

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Overhead and panel information
1. Overhead section
The overhead section is the panel section and the side pots, where I house the pilot’s MAP light and
the overhead aural speakers. In front of the box, is a part of the ceiling where my compass is
attached and the central pillar of the centre window. (The central pillar functions as a guide for the
wiring coming from the overhead).

Illustration 1 – General side-elevation drawing (version 3) – source: unknown

From the drawing above you can conclude the overhead is in total 1565mm long. The forward
section (containing the panels) measures 620 mm, the aft section (containing the circuit breakers and
maintenance panels) take up the remaining space. In my simulator setup, I don’t include the aft
section of the overhead. This due to space issues.

The forward overhead section, starts 318mm behind the window at a height of 1281mm above the
cockpit floor. Due to a little mess up in my design phase, my overhead starts at 303mm from the
(imaginary) window. The complete overhead section is inclined at appr. 15° upward. If you would
construct the aft overhead sections, you would end up at a height of 1752mm above the floor (not
counting the 38mm height difference of the cockpit floor).

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From the next drawing, we know that the most-forward point of the centre window starts 712mm
aft of the cockpit forward bulkhead. In my simulator, the cockpit forward bulkhead is moved more the
aft (again to reduce space) and is, in fact, the wall against which my flight deck is installed. The
712mm is reduced to 314mm.

This also brings the main visual screen closer and sits just at the end of the FDS glareshield. This
avoids the need of an extension of the glareshield and closes up everything rather nicely. This also
causes that the viewpoint setup of the software will be adjusted to match the actual view.

Illustration 2 – General side-elevation windows (version 2) – source: unknown

There is not a lot of information

available on the width of the overhead
section. We can only assume that it is
within the contains of the width of the
forward window, meaning less than
822mm.

Illustration 3 - 747-8 inside picture. Source: Lufthansa

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 Illustration 4 -General top shell view (version 2) – source: unknown

2. Overhead panels
On the panels, there is no clear information among the width and length. Most of the measurements
are compiled from measures found of panels which can be bought by various vendors. I based my
designs on the measurements I found of the Open Cockpit overhead panels, as I initially intended to
use this panels.

The panels can be allocated in 3 rows. A port row, containing the electrics, hydraulics, EEC, IRS,
cockpit lights and ELT. A central row, containing the landing/runway lights, fuel, engine start, fire
controls. And a starboard row, containing the navigation lights, pack, a/c, pneumatic controls.

The port and starboard row panels have a width of appr. 223mm and the central panels have a width
of 292mm. Based on this information we can assume that the overhead panel box must be appr.
740mm wide, taking in 1mm separation between the panels individually and 1mm separation on the
sides.

If we take the same separation as in the lateral division, we find that the overhead panel box must be
appr. 630mm long, matching the dimensions found in Illustration 1.

To allow access to the panels I made it possible to open the panel box. My panels are mounted on 2
aluminium T-shaped and 2 aluminium L-shaped bars, which run in the longitudinal orientation. To
allow easy removal, if necessary, I fixed the panels by means of four M4 screws and nuts. See further
for more information.

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Dimension list of the overhead panels1
Cockpit light control panel: 222,25 x 57,150 mm
Hydraulic system control panel: 222,25 x 123,800 mm
Electric system control panel: 222,25 x 219,075 mm
IRS control panel: 222,25 x 47,625 mm
EEC panel: 222,25 x 57,150 mm
ELT control panel: 222,25 x 57,150 mm
Blank Port side: 222,25 x appr 57mm
Landing/runway light control panel: 292,10 x 57,150 mm
Anti-ice and window control panel: 292,10 x 76,200 mm
Fuel pump control panel: 292,10 x 123,825 mm
Engine start and jettison control panel: 292,10 x 85,725 mm
Fire control panel: 292,10 x 180,975 mm
Miscellaneous control panel: 292,10 x 95,250 mm
Navigation light control panel: 222,25 x 57,150 mm
Pneumatic pack control panel: 222,25 x 133,350 mm
Air handling and temperature control panel: 222,25 x 142,875 mm
Pneumatic pressure control panel: 222,25 x 76,200 mm
Yaw damper and oxygen control panel: 222,25 x 57,150 mm
Cargo air flow control panel: 222,25 x 76,200 mm
Blank Starboard: 222,25 x appr 79mm

Illustration 5 - Overhead Panel Arrangement scheme

(please note the electrical systems panel should be 219mm and the port blank only 56mm)

1
I am not sure about why this level of detailed dimensions is necessary, but I believe that it comes from the conversion ‘inches to mm’.

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 3. Panel details
To design my own panels I used pictures of the various panels and analysed them in AutoCAD. As
every airline have their own specific requirements, Boeing produces all their wishes on the systems
and panels. There is no ordinary standard setup, so I included most of the options in my design.
Please also note that there is a difference between the PAX version and the freighter version of the
airliner. My design is based on the PAX version. In later updates I will add the possibility to switch to a
freighter.

In the next couple of pages I will guide you through most of the details of the overhead panels.
Please note that I use my own Korry replica design and I did not include Korry guards in my design, as
they are very difficult to find at a reasonable price.

All measurements are taken from the centre axis (x and y), unless clearly stated otherwise. All panels
have the same build up. They are composed of 3 layers white acrylic plastic plates (2mm thickness).
The layers are held together with M3 ball head bolts and screws.

The panels are fixed to my structure by means of M4 flat head bolts and screws. I only draw the
outlines of this on the first drawing (as they are standard for all the panels, except where otherwise
specified).

1.3.1. Cockpit light control panel

Illustration 6 – Picture representation ‘Cockpit light control panel’ (source: OpenCockpits)

Illustration 7 - Personal ‘Cockpit light control panel’ design

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 1.3.2. Hydraulic system control panel

Illustration 8 - Picture representation ‘Hydraulic system control panel’ (source: OpenCockpits)

Illustration 9 - Personal 'Hydraulic system control panel' design

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 1.3.3. Electric system control panel

Illustration 10 - Picture representation 'Electric system control panel' (source: OpenCockpits)

The electric system control panel has an extra layer of 2mm in the upper left corner where the
standby power switch is located

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 Illustration 11 - Personal 'Electric system control panel' design

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 1.3.4. IRS control panel

Illustration 12 - Picture representation 'IRS control panel' (source: OpenCockpits)

Illustration 13 - Personal 'IRS control panel' design

1.3.5. EEC panel

Illustration 14 - Picture representation 'EEC panel' (source: OpenCockpits)

Illustration 15 - Personal 'EEC panel' design

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 1.3.6. ELT control panel

Illustration 16 - Picture representation 'ELT control panel' (source: OpenCockpits)

Illustration 17 - Personal 'ELT control panel' design

Please note that on the ELT control panel, I added a LED to know when the ELT is activated. This is
purely decorative.

1.3.7. Landing/Runway light control panel

Illustration 18 - Picture representation 'Landing/Runway light control panel' (source: OpenCockpits)

Illustration 19 - Personal 'Landing/Runway lights control panel' design

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 1.3.8. Anti-Ice and Window Control panel

Illustration 20 - Picture representation 'Anti-ice and Window control panel' (source: OpenCockpits)

Illustration 21 - Personal 'Anti-ice and Window control panel' design

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 1.3.9. Fuel pump control panel

Illustration 22 - Picture representation 'Fuel system control panel' (source: OpenCockpits)

Illustration 23 - Personal 'Fuel system control panel' design

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 1.3.10. Engine start and Fuel jettison control panel

Illustration 24 - Picture representation 'Engine start and Fuel jettison control panel' (source: OpenCockpits)

Illustration 25- Personal 'Engine start and Fuel jettison control panel' design

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 1.3.11. Fire control panel

Illustration 26 - Picture representation 'Fire control panel' (source: OpenCockpits)

Illustration 27 - Personal 'Fire control panel' design

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 1.3.12. Miscellaneous control panel

Illustration 28 - Picture representation 'Miscellaneous control panel' (source: OpenCockpits)

Illustration 29 - Personal 'Miscellaneous control panel' design

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 1.3.13. Navigation light control panel

Illustration 30 - Picture representation 'Navigation light control panel' (source: OpenCockpits)

Illustration 31 - Personal 'Navigation light control panel' design

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 1.3.14. Pneumatic pack control panel

Illustration 32 - Picture representation 'Pneumatic pack control panel' (source: OpenCockpits)

Illustration 33 - Personal 'Pneumatic pack control panel' design

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 1.3.15. Air handling and Temperature control panel

Illustration 34 - Picture representation 'Air handling and Temperature control panel' (source: OpenCockpits)

Illustration 35 - Personal 'Air handling and Temperature control panel' design

* The C & W marking (11,5mm*) should be increased to about 14 to 15mm

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 1.3.16. Pressure control panel

Illustration 36 - Picture representation 'Pressure control panel' (source: OpenCockpits)

Illustration 37 - Personal 'Pressure control panel' design

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 1.3.17. Yaw Damper and Pax Oxygen control panel

Illustration 38 - Picture representation 'Yaw damper and PAX oxygen control panel' (source: OpenCockpits)

Illustration 39 - Personal 'Yaw damper and PAX oxygen control panel' design

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 1.3.18. Cargo Condition Air Flow control panel

Illustration 40 - Picture representation 'Cargo Condition Air Flow Rate control panel' (source: OpenCockpits)

Illustration 41 - Personal 'Cargo Condition Air Flow Rate control panel' design

1.3.19. Headphone and mic boom panel

As my overhead section is limited, I had to incorporate the
‘headphone and mic boom’ panel on the side of my overhead
box. Originally this panel is found above the middle side
window of the cockpit.

The panel is attached with 4 M3,5 bolhead wood screws. The

panel houses 2 3,5mm jack connections which are connected to
the audio system.

This panel consist out of a top plate only!

Illustration 42 - Headphone and mic boom panel

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Fabrication information / guidelines
1. 3D printing / CNC
To fabricate my panels I converted my Creality Ender3D printer in a small milling machine. I removed
the printers extruder head and replaced it with the flexible extension head of my Dremel multi tool.
To mount the Dremel extension head, I first printed a holder for this head, which I found on
Thingiverse (link in the footnote)2. To protect my printer, I installed one wooden layer, which I fixed
on the heated bed using the bolts from the calibration wheels. On top of this first layer I installed a
wooden waste plate. This second plate can easily be replaced as it is fixed in place by means of 5
woodscrews. On top of this waste plate, I mount the acrylic plate to be cut.

Illustration 43 - Ender3D conversion (waste plate installed) Illustration 44 - Ender3D conversion (ready for milling)

To hold down the acrylic plate I used a combination of clip-ons and 2,9mm woodscrews. The
woodscrews are positioned in the exact location where the later ball head screws are installed in the
panel (after pre-drilling the acrylic).

As a 3D printer is designed to build things up and not really to cut parts away, you cannot use the
normal 3D generating software to create the GCODE for the milling. So I transferred my drawings
from AutoCAD into Fusion 360, where I could write the GCODE more easily using some YouTube’s
help3.

As the panels consist out of 3 layers of acrylic, each layer has to be cut separately. And so, for each
layer, a new GCODE had to be written. In the earlier pages, I only showed the details over the top
plates. The details on the base and subbase panels are fairly the same for each panel. In the next
pages, you can find the cut-outs which are to be made in these layers of the panel.

To perform the cuts I used 2 different sets of drilling bits. The first cut was made with a 2mm drilling
bit and afterwards the cut was repeated with a 3mm drilling bit. With this way of working, I found

2
Thingiverse link: https://www.thingiverse.com/thing:3202418
3
YouTube link: https://www.youtube.com/watch?v=IJxqXk-wdJw&t=750s

Version 1 page 26 August 19, 2019

that, even though the GCODE was written for a 3mm drilling bit, that the cuts were much nicer and
smoother. This also prevented the bigger drilling bit getting stuck or running out of its track, as my
3D printer is not an actual CNC machine.

2. Base and subbase layer details

For every button, switch, korry, etc, there is a specific way of mounting the equipment to the panel,
and so it will also need specific cut-outs in the underlaying panels to firmly attach the equipment. E.g.
a potentiometer with a shaft diameter of 6mm, has an opening in the top plate of 10mm; an opening
of 20mm in the base plate and an opening of 10mm in the subbase plate. The base opening has to be
this wide to enable the potentiometer to be fixed with the original nut. The opening in the subbase
only has to be 10mm, so the fixing screw section of the potentiometer can pass through, and the
potentiometer is firmly attached.

TOPPLATE

2P/3P switch: Potentiometer:

Ø12mm Ø10mm

BASEPLATE

2P/3P switch: Potentiometer:

Ø24mm Ø20mm

SUBBASE PLATE

2P/3P switch: Potentiometer:

Ø12mm Ø10mm

Illustration 45 - Sketch 1

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 TOPPLATE
Annunciator: Rotary selector: Korry:
H: 14mm Ø10mm 22 x 22mm
L: 26mm
Korry with guard:
24 x 24mm

BASEPLATE
Annunciator: Rotary selector: Korry:
H: 12mm Ø20mm 30,5 x 30,5mm
L: 24mm

SUBBASE PLATE
Annunciator: Rotary selector: Korry:
H: 16mm Ø10mm 26 x 26mm
L: 30mm

Illustration 46 - Sketch 2

The other equipment, like starter switches, pull up switches, small pushbuttons, etc, are mounted in
the same manner, depending on the specific equipment used. In my setup, the starter switches and
pushbutton switches, have a mounting diameter of 8mm in the subbase and an opening of 20mm
diameter in the baseplate. The pull-up switch has a mounting diameter of 7mm and a baseplate
opening of 20mm diameter.

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 3. Painting and engraving
Before I painted my panels, I assembled the plates together, with the ball head head screws and
respective nuts. After a quick sanding, I painted the panels using ‘buffel brown’ spray paint, which I
bought in my local hardware store.

When the paint is dry, the panel is dismantled again and the top plate is engraved using a 0,8mm
engravement spherical needle. The engravement itself runs only 0,1mm deep into the panel, so only
the paint is scratched off. To correct any misfortunes, I used my wife’s nail cleaning mini-mill, to
correct where necessary.

4. Printed elements
4.1. Korry replicas
The Korry replicas I use are homemade and use a big ON-OFF pushbutton switch and two (2) 3mm
white LEDs. The Korry switch itself is composed out of 3 printed elements: a housing for the switch, a
head for the LED lights and indicators, and a ring to secure the Korry firmly to the panel.

The switch and LEDs are independent, meaning the switch and LEDs have to be synchronised with
some software help. The switches are connected to the INPUT (Open Cockpits) board, the LEDs to the
OUTPUT (Open Cockpits) board. Each LED has its own resistor and all LEDs are mounted in a parallel
sequence.

As you can see from the panel details section, the Korry housing is mounted through the subbase
panel and is held fast with the ring below the panel. I only installed the ring after the Korry was
almost fully assembled and only the indicator plates had to be installed.

Prior installing the head, the LEDs must be inserted and soldered without the resistors as the
resistors are located outside of the housing. This makes that the wires attached to the LEDs must be
led through the holes in the bottom of the housing around the switch.

The indicator heads I use for this Korry replicas are purchased NKK inserts. These indicator heads can
be opened and an indicator sheet can be inserted. The opening of the Korry head is made so that
these can fit in perfectly without any glue and they can easily be removed by means of a flat end
screwdriver. To avoid light diffusion on the indicator, I placed a H-shaped insert in the bottom of the
indicator insert, and I painted the outsides of the inserts black. This avoids that if the upper LED is
activated the lower part of the indicator is lit as well.

Illustration 47 - Korry replica design

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 Illustration 48 - Korry replica picture

Pushbutton switch NKK insert

Vendor: Digi-key Vendor: Digi-key
Artnr: EG5933-ND Artnr: AT3076JB-ND

3mm LED – white – 1000mcd/20mA Metal film resistor – 100Ohm/1W

Vendor: Conrad
Vendor: Conrad
Artnr: 1677271
Artnr: 1603069

Due to the dens packing of Korry switches, e.g. the fuel pump control panel, some housings are
printed together per 2 or 4 housings. This is done just to have the Korry switches on the correct
position in the panel.

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 4.2. Annunciators
The annunciators I use are, just like the Korry replicas, homemade and produced with my 3d printer.
The annunciator is composed out of 2 printed elements: a housing and a head. The housing clicks
around the head and holds the baseplate of the panel in between (this is done by incorporating a
sharkteeth holderclips in the design). The housing holds the two (2) 3mm LEDs and the head holds
the indicator sheet and a 2mm thick transparent plexi glass plate. The plexi glass plate is mounted in
the opening of the head without glue, but cannot be removed with a screwdriver.

Like the Korry LEDs, these LEDs have their own resistor connected to them (see above for product
information), but they are bound together to one input and one output line.

Illustration 49 - Annunciator design - top view

Illustration 50 - Annunciator design - side view

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 4.3. Starter switches
The starter switches are modified pull-up switches with light which were purchased4. The purchased
switches had mushroom-like heads, which contained a 12v lamp, which I found too big for the
purpose of starter-switch. Due to de construction of the switch, I could easily remove the lamp
holder and the connection rod. I redesigned this holder into a new head to hold a single 3mm LED.

Illustration 51 - Original starter switch Illustration 52 - Original start switch layout

Illustration 53 - Redesigned starter knob - bottom view

Illustration 54 - Redesigned starter knob - side view

In order to keep the switch working when closed (NC), I had to remove the lower connector from the
original. On the bottom view, you can see that this connector has to be glued to the new design in
order to make a connection between the newly designed starter knob and the original switch
housing.

The upper and lower part of the starter knob are glued together after the switch is inserted in the
panel. The LED wiring runs through the 3mm hole in the middle of the knob and the cap closes the
knob. The cap is printed transparently.

4 Vendor: Conrad - Art nr: 1587798

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 4.4. Fire handles
The fire handles are fully printed after my own design. The
handles are composed of a base rotary holder (housing the rotary
selector), a holder plate (housing the reset p/b and the central
shaft, to facilitate the pull-out function), an inner rod (to guide the
handle) and the handle itself. The handle itself is assembled out
of 3 elements; a base, a LED holder and a cover with the
indications printed in.

The movement of the rotary switch is blocked when the handle is

not pulled out. This is made possible due to a guide in the central
shaft and a M4 screw. Till the point the handle is fully pulled out,
the screw does not allow the handle to turn left or right. Once this
point is passed, the screw-guide opens and the user can turn the
handle (to activate the extinguishing agent). To keep the handle
Illustration 55 - Fire handle design
connected to the rotary switch, the shaft of the switch is (3D view)
connected with an inner rod. The inner rod is screwed tight to the
shaft and has a half-moon design to transfer the rotary movement of the handle to the switch. This
half-moon shape also allows to move the handle easily over the shaft in and out.

The switch base slides in the holder plate, this I have done to have a more easy access to the shaft of
the switch and also to be able to fix the rotary switch firmly by its original nut.

Illustration 56 - Base rotary holder (top view) Illustration 57 - Base rotary holder (side view)

Illustration 58 - Holder plate (top view) Illustration 59 - Holder plate (front view)

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 Illustration 60 - Inner rod (side view) Illustration 61 - Inner rod (top view)

Illustration 63 - Fire handle (top view)

Illustration 62 - Fire handle (side view)

Illustration 65 - Picture representation of wired LED holder

Illustration 64 - Fire handle LED holder (top view)

Illustration 67 - Fire handle cover (side view)

Illustration 66 - Fire handle cover (top view)

The handle houses three (3) 3mm LED lights, fixed on the LED holder plate. Each LED has its own
resistor and all 3 LEDs are connected to a mutual in-/outline, which runs through the shaft of the
handle. The covers are initially printed with transparent PLA. The outside of the handle is painted
black, and the inside is coloured with a red permanent marker. If you would use red paint, I presume
that the lights will be blacked out too much. The number marking on top of the cover is also coloured
with the red marker, after the black paint has been removed from the inscription. All inscriptions are
printed in the cover and are painted white. Later consideration, I found that on some fire panels the
lower part of the handle is painted in the same colour as the panel itself.

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 4.5. Outlet valve indicators
The outlet valve indicators of the ‘pressure control panel’ are operated by two micro-servo towers,
type MG90S5. These micro-servo’s are mounted on a printed indicator plate, which also includes the
inscriptions of the valve position by means of 2 printed needles. The micro-servo towers ran through
the indicator plate and the needles are directly connected to the servos. The servo’s have an 270°
operating range, so no modifications have to be done to this equipment, as the indication is only
180°. In the bottom of the indicator plate, the servos can be mounted in the printed openings and
they are attached by the original screws (M2) (diameter 1,8mm mounting holes for the screws, so
the screws can be firmly tightened).

The plate itself is fixed to the panel by the panels ball head screw bolts. To secure everything nice
and tight, I also added glue to the plate and the baseplate of the ‘pressure control panel’.

Illustration 68 - Outlet valve indicator plate (top view)

Illustration 69 - Outlet valve indicator plate (bottom view)

5
https://www.banggood.com/6X-Towerpro-MG90S-Metal-Gear-RC-Micro-Servo-p-1072260.html?rmmds=myorder&cur_warehouse=CN

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 Illustration 70 - Outlet valve indicator plate (front view)

The indicator plate is printed with black PLA and is painted with matt black paint. The needles and
indications are painted white. After the plate has been attached to the ‘pressure control panel’, the
top covers are installed. To create the glass look, I inserted (and glued) a fine plastic sheet, cut out of
a food preservation bin, between the top covers and the top plate of the panel.

Illustration 71 - Top cover outlet valve indicators

4.6. Fire horn (replica)

The fire horn is a straight forward print. The horn is attached with 4 M3 ball head screws to the
foreseen cut out in the ‘Fire control panel’.

Illustration 73 - Fire horn (side view)

Illustration 72 - Fire horn (top view)

Version 1 page 36 August 19, 2019

 4.7. MAP light
This MAP light design is based on an idea (and construction) I found from a fellow cockpit builder
who is building a 737-800 flight deck6. I adjusted his design to meet my own
requirements of details, but basically it remains the same.

The MAP light is composed out of 5 printed elements; the housing (3

elements), the holder and the head. The 3 housing elements are glued
together and is used to house one 1,8W LED lamp (GU4 MR11 12V LED
spot)7.

The lamp is held in the housing by the head. The head of the MAP lamp is screwed down with 3
M3x6mm set screws. Inside the head, I placed a thin milky shade plastic cover. The lamp is driven by
a transformer, which is also mounted inside the overhead section. It should be possible to regulate
the voltage (and the intensity of the light) via a potentiometer, which is located on the captain’s side
glareshield control board, but I still have to connect this, and test this out.

Illustration 75 - MAP light housing details

Illustration 74 – MAP light general dimensions

Illustration 77 - MAP light head details

Illustration 76 - MAP light head general dimensions

6 Flightdeck 737 - https://www.flightdeck737.be/

7 LEDZ24 - https://www.ledz24.be/mr11-gu4-g4-led-spot-12-24-volt-24-watt.html

Version 1 page 37 August 19, 2019

 4.8. Compass
This compass design is based on the design of J. Katz8, who developed a wet compass for his 737
simulator. I adapted his design to fit the needs of a 747. My compass is also using a stepper-motor
28BYJ-48 and an Arduino board. The compass rose is mounted on the stepper-motor, which in total
is fixed on a holding plate. The holding plate slides into the back of the compass housing. So far, the
similarities with Josh’s design.

I incorporated a dimmer switch which dims the two (2) LEDs inside the compass house if required.
The dimmer is mounted in the front plate of the compass. The compass concept contains 5 printed
elements; the housing itself, the front cover, the holding plate, the compass rose and the mounting
bracket. The compass rose is printed in 3 parts (upper, middle and lower part) and has a small
magnet in place, which can be used to calibrate the compass rose using a hall effect sensor.

Illustration 78 - Compass house (front view) Illustration 79 - Compass house (side view)

Illustration 81 - Compass house (top view)

Illustration 80 - Compass house (back side)

The compass house is left open at the backside. The compass is also the forward part of my central
pillar design/construction, which will later be added, to hide the cables coming and going to the
overhead section.

The holding plate slides in the compass housing, this is done for easy access when the compass is
installed and requires maintenance. At the last moment, I decided to screw fast the holding plate, this
because the plate could move to easily.

8 Thingiverse: https://www.thingiverse.com/thing:3597509

Version 1 page 38 August 19, 2019

 Illustration 83 – Compass holding plate (side view)

Illustration 82 – Compass holding plate (top view)

Illustration 84 - Compass rose (top view - sectional)

Illustration 86 - Compass rose and holding plate assembled

Illustration 85 - Compass rose (side view - sectional)
(incl LEDs)

Illustration 89 - Front cover

Illustration 87 - Front cover (front view) (side view)
Illustration 88 - Front cover (back view)

Version 1 page 39 August 19, 2019

Overhead box construction
5.1. Panel box
The panel box, like the complete overhead section, is made up off 4mm thick, 8mm thick MDF plate
and 27x27mm woodbeams. The panels itself are mounted on 2 aluminium T-shape (20x20mm) and 2
aluminium L-shape profiles (10x10mm).

Illustration 90 - Panel box (top view)

Illustration 91 - Panel box (side view)

Note that on beam nr 3 there are 2 cut outs made, each 30mm wide
and 4mm deep) these cut outs are necessary for later supports. On
top of the nr 3-beam, there is a secondary beam to level out the T-
shaped profiles to this nr 3-beam. This additional beam will have 2
Illustration 92 - nr 3 top beam cut outs
slots cut out to house these profiles.

Version 1 page 40 August 19, 2019

 Illustration 93 - 3D representation of the panel box

Length of beams (27x27mm):

1 2 x 560mm
2 2 x 686mm
3 1 x 740mm
4 2 x 334mm
5 2 x 39mm
6 2 x 42mm

The extensions pots ‘5A & 5B’ – ‘6A & 6B’ each have an 8mm diameter hole drilled through them.
These holes will later house the bolts to attach the panel box to the overhead box. But these bolts
will also be the axis around which the panel box will open for maintenance. These holes are drilled
27mm above the bottom of the piece.

Nr 5’s have a slot cut out at the side in longitudinal orientation to house the L-shape profile. The cut
out section measures 9mm in height and 1mm in depth. The nr 6’s have a similar slot cut out, but in
the middle of the top, to house the T-shape profiles. This slot is 13mm deep.

Illustration 94 - 5A & 5B detailed Illustration 95 - 6A & 6B detailed

Version 1 page 41 August 19, 2019

The 2 side liners, adjacent to 1A & 1B, each measure 630mm in length and 56mm in height, have a
milled section of 625mm x 28mm. These liners are made off 4mm thick MDF sheet. The milled out
section, with a depth of 1mm houses the aluminium L-shape profile for mounting the panels.

Illustration 96 - Panel box - side liners

The aft liner can be completed by 1 sheet of 8mm MDF or with 2 sheets of 4mm MDF. The aft liner
measures 748mm in length and 56mm in height. On this liner the locks 9 will be installed at regular
intervals.

Illustration 97 - Panel box - aft liner (aft view)

9 Locks: https://nl.aliexpress.com/item/32730303749.html?spm=a2g0s.9042311.0.0.27424c4dUi7RO5

Version 1 page 42 August 19, 2019

 5.2. Overhead box
The overhead box is, just like the panel box, made of wood. The overhead box houses the panel box
and the side pots, containing the map light and the aural overhead speakers. It also houses the
electronic I/O cards of my panel box. The ‘headphone / mic boom’ panel is also installed on this box.

My overhead box is foldable, to conserve space, in the room while I am not using my flightdeck. The
elements needed to fold the overhead are not incorporated in this document, nor on the drawings.

This box is constructed using 27 x 27mm wood beams, screwed together. The outside is covered with
8mm MDF wood sheets (to increase rigidity). The box is painted in a Boeing-like cream colour. The
box measures in total 988mm by 738mm.

Illustration 98 - Overhead box construction (top view)

Illustration 99 - Overhead box construction (side view)

Version 1 page 43 August 19, 2019

Length of beams (27x27mm):

1 2 x 705mm
2 3 x 918mm
3 2 x 257mm
4A&D 2 x 65mm
4B&C 2 x 60mm
5 4 x 42mm
6 4 x 42mm
7 2 x 96mm

The nr 4 beams have each an 8mm diameter hole drilled through them, this to connect the swivel
axis of the panel box to the overhead box. The beams are connected to the forward transversal (2A).

Illustration 100 - Overhead box construction (3D view)

Illustration 101 - Overhead box construction - forward transversal (2A) (front view)

In this forward transversal (2A) 2 cut outs have been made to align the longitudinal beams (4A & 4B)
of the panel box. These cut outs run over the entire beams width and have a depth of 9mm.

Version 1 page 44 August 19, 2019

 Illustration 102 - Overhead box construction - middle transversal (2B) (front view)

The middle transversal (2B) beam has, similar to the forward one (2A), 2 cut
outs to align the longitudinal beams of the panel box. These cut outs are the
same as on the forward one.

Next to this cut out, the side pot supports (5A to 5D) are connected to this
transversal.
Illustration 103 - Side pot
supports #5

Illustration 104 - Overhead box construction - aft transversal (2C) (front view)

The aft transversal (2C) has no cut outs for the panel box nr 4 beams, as the beams of the panel box
don’t run so far back. However there are 2 cut outs made to secure the panel box supports (7A & 7B).
These supports run 2mm into the aft transversal beam (see drawing below). The panel box support
nr 7, which are connected to the aft transversal, have a centre cut out of 13mm deep. This to
accommodate the panel box T-shape profiles.

Illustration 105 - Overhead box construction - aft transversal (2C) (top view)

The side covers are made of 8mm MDF wood sheets. Prior installing the outside side covers, the
internal construction of the side pots must be installed (see further). This is done because otherwise
the access would be very limited.

Illustration 106 - Overhead box construction - inside side covers

Version 1 page 45 August 19, 2019

I made 2 addition cut outs in the inside covers, this to allow access to the audio speakers, which are
located near the aft of these covers. These cut outs were made on side, after all construction was
completed. Depending on the size of the speakers you use, you will have to make a similar cut out.

The opening for the audio connections for the headphones and mic boom are not marked on the
drawings. These openings depend on where the user wants to have his connection.

Illustration 107 - Overhead box construction - outside covers

Illustration 108 - Overhead box construction - aft cover

The side pot internal supports are at the

front of the side pots. Essentially these are
small wooden beams (27 x 27mm) to
support the external covers of the overhead
box and the side pots.

8 2 x 95mm
9 2 x 23mm
10 2 x 63mm
11 2 x 45mm
12 1 x 918mm
13 2 x 15mm

Illustration 109 - Side pot internal supports (3D view)

Version 1 page 46 August 19, 2019

 Illustration 110 - Side pot internal supports (side view) Illustration 111 - Side pot internal support #13 (details)

As mentioned earlier, the side covers of the overhead box are made off 8mm MDF wood sheets, so is
the covers of the side pots interior. Except for the forward cover, this cover is made off 12mm MDF
wood, because of its supporting function. I have installed 3 hinges on this forward cover, to be able
to rotate the overhead box (incl. panel box) upwards.

Illustration 112 - Side pot covers (side view)

The aft interior cover (310mm x 103mm) houses the overhead aural speaker. Before installing this
cover, a cut out has to be made and the speaker plates have to be inserted (eventually with the
speakers). Along the cut out a section of 10mm has to be removed (depth 2mm) to allow the speaker
plate to be sunk into to interior cover. The same milling is done on the bottom of the speaker plate.

Illustration 113 - Side pot covers - aft cover (speaker plate cut out)

Version 1 page 47 August 19, 2019

 Illustration 114 - Speaker plate (top view) Illustration 115 - Speaker plate (bottom view)

When I constructed the inside section of the speaker plate I didn’t had a 3D printer at my disposal. If I
would reconstruct this part, I would print the inside section, rather than to cut and drill it.

Version 1 page 48 August 19, 2019

 5.3. Front section
The forward cover of the overhead box is connected to the
front section of my overhead. This front section is not foldable
and is fixed to the wall. The connection between the 2 parts is
made by 3 heavy duty hinges I purchased at the local hardware
store.

The front section of the overhead is also made up off 12mm

MDF wood. It has a covered edge to represent the front
window of the airplane. The beams mentioned on the drawing
below are added to support the overhead section and Illustration 116 - Overhead box forward
connected it to my wall plates. cover (details)

Illustration 117 - Front section (top view)

Illustration 118 - Front section (side view)

Version 1 page 49 August 19, 2019

LIST OF ILLUSTRATION
Illustration 1 – General side-elevation drawing (version 3) – source: unknown ................................................................................................ 5
Illustration 2 – General side-elevation windows (version 2) – source: unknown ............................................................................................... 6
Illustration 3 - 747-8 inside picture. Source: Lufthansa ...................................................................................................................................... 6
Illustration 4 -General top shell view (version 2) – source: unknown ................................................................................................................ 7
Illustration 5 - Overhead Panel Arrangement scheme ..................................................................................................................................... 8
Illustration 6 – Picture representation ‘Cockpit light control panel’ (source: OpenCockpits) ............................................................................ 9
Illustration 7 - Personal ‘Cockpit light control panel’ design .............................................................................................................................. 9
Illustration 8 - Picture representation ‘Hydraulic system control panel’ (source: OpenCockpits) .................................................................... 10
Illustration 9 - Personal 'Hydraulic system control panel' design ..................................................................................................................... 10
Illustration 10 - Picture representation 'Electric system control panel' (source: OpenCockpits) ..................................................................... 11
Illustration 11 - Personal 'Electric system control panel' design ...................................................................................................................... 12
Illustration 12 - Picture representation 'IRS control panel' (source: OpenCockpits) ........................................................................................ 13
Illustration 13 - Personal 'IRS control panel' design ......................................................................................................................................... 13
Illustration 14 - Picture representation 'EEC panel' (source: OpenCockpits).................................................................................................... 13
Illustration 15 - Personal 'EEC panel' design .................................................................................................................................................... 13
Illustration 16 - Picture representation 'ELT control panel' (source: OpenCockpits) ........................................................................................ 14
Illustration 17 - Personal 'ELT control panel' design......................................................................................................................................... 14
Illustration 18 - Picture representation 'Landing/Runway light control panel' (source: OpenCockpits)........................................................... 14
Illustration 19 - Personal 'Landing/Runway lights control panel' design .......................................................................................................... 14
Illustration 20 - Picture representation 'Anti-ice and Window control panel' (source: OpenCockpits)............................................................ 15
Illustration 21 - Personal 'Anti-ice and Window control panel' design............................................................................................................. 15
Illustration 22 - Picture representation 'Fuel system control panel' (source: OpenCockpits) .......................................................................... 16
Illustration 23 - Personal 'Fuel system control panel' design ........................................................................................................................... 16
Illustration 24 - Picture representation 'Engine start and Fuel jettison control panel' (source: OpenCockpits)............................................... 17
Illustration 25- Personal 'Engine start and Fuel jettison control panel' design ................................................................................................ 17
Illustration 26 - Picture representation 'Fire control panel' (source: OpenCockpits) ....................................................................................... 18
Illustration 27 - Personal 'Fire control panel' design ........................................................................................................................................ 18
Illustration 28 - Picture representation 'Miscellaneous control panel' (source: OpenCockpits) ...................................................................... 19
Illustration 29 - Personal 'Miscellaneous control panel' design ....................................................................................................................... 19
Illustration 30 - Picture representation 'Navigation light control panel' (source: OpenCockpits) .................................................................... 20
Illustration 31 - Personal 'Navigation light control panel' design ..................................................................................................................... 20
Illustration 32 - Picture representation 'Pneumatic pack control panel' (source: OpenCockpits) .................................................................... 21
Illustration 33 - Personal 'Pneumatic pack control panel' design..................................................................................................................... 21
Illustration 34 - Picture representation 'Air handling and Temperature control panel' (source: OpenCockpits) ............................................. 22
Illustration 35 - Personal 'Air handling and Temperature control panel' design .............................................................................................. 22
Illustration 36 - Picture representation 'Pressure control panel' (source: OpenCockpits) ............................................................................... 23
Illustration 37 - Personal 'Pressure control panel' design ................................................................................................................................ 23
Illustration 38 - Picture representation 'Yaw damper and PAX oxygen control panel' (source: OpenCockpits) ............................................... 24
Illustration 39 - Personal 'Yaw damper and PAX oxygen control panel' design................................................................................................ 24
Illustration 40 - Picture representation 'Cargo Condition Air Flow Rate control panel' (source: OpenCockpits) ............................................. 25
Illustration 41 - Personal 'Cargo Condition Air Flow Rate control panel' design .............................................................................................. 25
Illustration 42 - Headphone and mic boom panel ............................................................................................................................................ 25
Illustration 43 - Ender3D conversion (waste plate installed) ........................................................................................................................... 26
Illustration 44 - Ender3D conversion (ready for milling) .................................................................................................................................. 26
Illustration 45 - Sketch 1 .................................................................................................................................................................................. 27
Illustration 46 - Sketch 2 .................................................................................................................................................................................. 28
Illustration 47 - Korry replica design ................................................................................................................................................................ 29
Illustration 48 - Korry replica picture ............................................................................................................................................................... 30
Illustration 49 - Annunciator design - top view ................................................................................................................................................ 31
Illustration 50 - Annunciator design - side view ............................................................................................................................................... 31
Illustration 51 - Original starter switch ............................................................................................................................................................ 32
Illustration 52 - Original start switch layout ..................................................................................................................................................... 32
Illustration 53 - Redesigned starter knob - bottom view.................................................................................................................................. 32
Illustration 54 - Redesigned starter knob - side view ....................................................................................................................................... 32
Illustration 55 - Fire handle design (3D view) .................................................................................................................................................. 33
Illustration 56 - Base rotary holder (top view) ................................................................................................................................................. 33
Illustration 57 - Base rotary holder (side view) ................................................................................................................................................ 33
Illustration 58 - Holder plate (top view) ........................................................................................................................................................... 33
Illustration 59 - Holder plate (front view) ........................................................................................................................................................ 33
Illustration 60 - Inner rod (side view) ............................................................................................................................................................... 34
Illustration 61 - Inner rod (top view) ................................................................................................................................................................ 34
Illustration 62 - Fire handle (side view) ............................................................................................................................................................ 34
Illustration 63 - Fire handle (top view) ............................................................................................................................................................. 34
Illustration 64 - Fire handle LED holder (top view) ........................................................................................................................................... 34
Illustration 65 - Picture representation of wired LED holder ........................................................................................................................... 34

Version 1 page 50 August 19, 2019

Illustration 66 - Fire handle cover (top view) ................................................................................................................................................... 34
Illustration 67 - Fire handle cover (side view) .................................................................................................................................................. 34
Illustration 68 - Outlet valve indicator plate (top view) ................................................................................................................................... 35
Illustration 69 - Outlet valve indicator plate (bottom view) ............................................................................................................................. 35
Illustration 70 - Outlet valve indicator plate (front view) ................................................................................................................................. 36
Illustration 71 - Top cover outlet valve indicators ............................................................................................................................................ 36
Illustration 72 - Fire horn (top view) ................................................................................................................................................................ 36
Illustration 73 - Fire horn (side view) ............................................................................................................................................................... 36
Illustration 74 – MAP light general dimensions ............................................................................................................................................... 37
Illustration 75 - MAP light housing details ....................................................................................................................................................... 37
Illustration 76 - MAP light head general dimensions ....................................................................................................................................... 37
Illustration 77 - MAP light head details ............................................................................................................................................................ 37
Illustration 78 - Compass house (front view) ................................................................................................................................................... 38
Illustration 79 - Compass house (side view) ..................................................................................................................................................... 38
Illustration 80 - Compass house (back side) ..................................................................................................................................................... 38
Illustration 81 - Compass house (top view) ...................................................................................................................................................... 38
Illustration 82 – Compass holding plate (top view) .......................................................................................................................................... 39
Illustration 83 – Compass holding plate (side view) ......................................................................................................................................... 39
Illustration 84 - Compass rose (top view - sectional) ....................................................................................................................................... 39
Illustration 85 - Compass rose (side view - sectional) ...................................................................................................................................... 39
Illustration 86 - Compass rose and holding plate assembled (incl LEDs) .......................................................................................................... 39
Illustration 87 - Front cover (front view) .......................................................................................................................................................... 39
Illustration 88 - Front cover (back view) .......................................................................................................................................................... 39
Illustration 89 - Front cover (side view) ........................................................................................................................................................... 39
Illustration 90 - Panel box (top view) ............................................................................................................................................................... 40
Illustration 91 - Panel box (side view) .............................................................................................................................................................. 40
Illustration 92 - nr 3 top beam cut outs ........................................................................................................................................................... 40
Illustration 93 - 3D representation of the panel box ........................................................................................................................................ 41
Illustration 94 - 5A & 5B detailed ..................................................................................................................................................................... 41
Illustration 95 - 6A & 6B detailed ..................................................................................................................................................................... 41
Illustration 96 - Panel box - side liners ............................................................................................................................................................. 42
Illustration 97 - Panel box - aft liner (aft view) ................................................................................................................................................. 42
Illustration 98 - Overhead box construction (top view) ................................................................................................................................... 43
Illustration 99 - Overhead box construction (side view) .................................................................................................................................. 43
Illustration 100 - Overhead box construction (3D view) .................................................................................................................................. 44
Illustration 101 - Overhead box construction - forward transversal (2A) (front view) ..................................................................................... 44
Illustration 102 - Overhead box construction - middle transversal (2B) (front view) ....................................................................................... 45
Illustration 103 - Side pot supports #5 ............................................................................................................................................................. 45
Illustration 104 - Overhead box construction - aft transversal (2C) (front view) ............................................................................................. 45
Illustration 105 - Overhead box construction - aft transversal (2C) (top view) ................................................................................................ 45
Illustration 106 - Overhead box construction - inside side covers ................................................................................................................... 45
Illustration 107 - Overhead box construction - outside covers ........................................................................................................................ 46
Illustration 108 - Overhead box construction - aft cover ................................................................................................................................. 46
Illustration 109 - Side pot internal supports (3D view)..................................................................................................................................... 46
Illustration 110 - Side pot internal supports (side view) .................................................................................................................................. 47
Illustration 111 - Side pot internal support #13 (details) ................................................................................................................................. 47
Illustration 112 - Side pot covers (side view) ................................................................................................................................................... 47
Illustration 113 - Side pot covers - aft cover (speaker plate cut out) ............................................................................................................... 47
Illustration 114 - Speaker plate (top view) ....................................................................................................................................................... 48
Illustration 115 - Speaker plate (bottom view) ................................................................................................................................................ 48
Illustration 116 - Overhead box forward cover (details) .................................................................................................................................. 49
Illustration 117 - Front section (top view) ........................................................................................................................................................ 49
Illustration 118 - Front section (side view) ....................................................................................................................................................... 49

Version 1 page 51 August 19, 2019