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Standby Gauge Bezels Discussion

(Original thread started on 08-15-11 by Ron Rollo)

Standby Gauge Bezels SPEED, HSI and Altimeter by Project45!

Ron 974


It is time to get back to work on the standby gauges. One of the things that I had to master was finding a way to get the rotary encoder built into the side of the altimeter. It turns out that there is not a rotary encoder small enough to just stick in in there while at the same time keeping the gauge to scale. So what we have to do is file, grind, sand and shave the encoder down to size. In other words, put the little guy on a diet!


This set of two completed is $75. Or $30 for the airspeed gauge (left) and $45 for the altimeter gauge (right). They are held in place on the MIP with double sided sticky tape for super easy installation:

Ron 975


NOTE: The lens are still protected with paper.


(Posted by Shane Barnes on 08-16-11)

Hey guys, I received the standby gauges from Ron several weeks ago and they are awesome. They really add to the MIP.


(Posted by Ron Rollo on 08-17-11)

I have taken my MIP out to do some work on the RMUs. While I have the MIP out, it is a chance to show everyone what the back side of the standby gauges look like especially where the encoder is.


A side note, in case some of you did not know this, there are at least two standby altimeter designs that you will find in the Lear45. The one I have chosen is the smaller design, which is more challenging to fit the encoder into it. But I personally like the way it looks compared to the other model.


Anyway, here is a photo of the back side of the gauges:

Ron 976


Another close up showing how everything has to remain low profile because of the LCD screens being right there. You will notice in the previous photo that I am planning to use screw post for the center HSI gauge and the CWP:

Ron 977


This way I do not have to pull the MIP back out. I just have to MAKE SURE that the screws are not long enough to touch the LCD screens. And the front view of the two gauges and screw post in place:

Ron 978


Over the past two weeks I have been thinking, planning and drawing the HSI center standby gauge as it is high priority because for a few of us, it is the last piece of the puzzle before we can install the MIP once and for all. I had several goals that I had to achieve and I think I have met them all.


The first major goal was that I wanted to back light the degree of turn scale and the aircraft symbol. As you know, we have all adopted the LCD screen behind the MIP and these three standby gauges work great because of the work Dave Ault has done. (Thank you Dave!) The LCD screen lights up the gauges, however, I wanted to make as much of the HSI with real parts so that only the "gyro" in Dave's program is seen moving on the LCD screen. Therefor, the scale may not look like it is illuminated compared to the other two gauges if it did not have it's own lighting.


The second major thing that I wanted to work into my design is an adjustable aircraft symbol. I wanted to be able to move the plane up and down to slightly adjust it to the pilot's eye point. It is a small detail and something that will hardly ever get touched but I think it is cool!


This is a real Lear45 HSI:

Ron 979


I wanted to post this up so you guys can see the detail of it and what I am putting into my design.


Here is my prototype HSI. I have been working on it for the past four days.  The aircraft symbol and knob have not been completed yet:

Ron 980


I am using post fasteners to attach the HSI to the MIP:

Ron 981


I am using four SMD LED's to light up HSI without the aircraft symbol installed yet.

Ron 982


And here is the HSI a day later with the aircraft symbol:

Ron 983

(You will note the the A/C symbol is slightly off center. It's a prototype!)


This photo shows the A/C symbol adjusted to it's max height:

Ron 984


I used .032" double sided copper clad to make the frame work to the A/C symbol. It is super strong, strong enough to stand on it like a spring board believe it or not!


Here is is adjusted down:

Ron 985


All of the HSI's that I send out will be sealed closed to keep all the parts from falling out. By the way, now I know what it is like to build a watch!


I have a little tweaking and tuning to do but with that said, I would say I am 95% there. I will need one more week to complete the knob before I start a production run. Speaking of the knobs, I will include the art work "PULL TO CAGE" on the face of the knobs.


NOTE: This is a function that will not be available obviously!


If you would like to get on the list, either post here or email me.

The price will be $165.


(Posted by Dave Ault on 11-10-11)

Great work Ron, glad I put the option of having just the gyro in now. Look forward to seeing it with the image behind it.


(Posted by Mark Speechley on 11-12-11)

I think I'm safe in saying that we all greatly appreciate the effort you put into your designs and construction. You have made our dreams of a cockpit infinitely easier to achieve.  A big Thank You.


(Posted by Ron Rollo on 11-22-11)

Just a real quick weekly update on the HSI production.  I am about 50% complete with cutting out 10 sets and 25% complete with the overall process of building them up. Lots of small detail and lots of hand time as you can imagine:

Ron 986


The artwork to the face of the knobs, "PULL TO CAGE" came out nice! But please don't pull it when you get it!!! Make sure you brief your guest pilots that at least this part of the knob is only for show:

Ron 987


I have four major parts built into this knob. It is not an exact replica of the real one but it is sure gonna be close. If you notice the white ring around the artwork, that is actually a guide line so that I can carve a 45 degree bevel into the cap just like the real knob.


I have twelve knobs completed. They turned out better than I could have hoped for when I was trying to figure out how I was going to go about it. Each knob has two pieces made with the CNC, one piece cut on a laser and two pieces that I picked up at the hardware store:

Ron 988


Each one already has the set screw installed. You will also notice that I have trimmed the edge of the knob cap by giving it a 45 degree bevel. This bevel only goes half way down the 1/8th inch cap. I used the white laser engraved rings as a guide to make them as close to perfect as I could get them.


Just a quick update on the HSI progress. I have ALL the parts cut out for ten sets and I am about 40% complete with building them all up. Next week I should start shipping them out. For those on the list, I will email you when they are ready.


I have finally finished the batch of HSI's! Here is a photo of all ten together including a Altimeter and an Airspeed bezel:

Ron 989


Seven of the HSI's are accounted for. I still have three that need a home. The HSI's by themselves are $165 each including shipping world wide:

Ron 990


If you need the complete set of three, they are $240 including shipping word wide.

Ron 991


(In case your not aware, the HSI is back lit and the artificial aircraft can be adjusted up and down.)


(Posted by Will Sasse on 01-03-12)

Superb work Ron! Looking forward to seeing for real.  Does it mount to the panel using double sided sticky tape like the other two gauges?


(Posted by Ron Rollo on 01-03-12)

Hey Will, not this one. I am using screw post fasteners that have to be put through the three holes on the MIP from the back side and super glued in place to keep them from moving or turning when fasten from the front side. (Only three holes, the fourth would be where the knob is in the bottom right hand corner) So you have to remove the MIP to install the HSI, which is why I was hell bent on completing these so we don't have to pull the MIP back out any time soon. The post and the screws are included with the HSI, so no worries.


I have just completed my third batch of HSI bezels.  Of this six pack, I have three available. Email me if you would like one:

Ron 992


Here is a photo of Dave's gauges behind the bezels!

Ron 974


(Posted by Terry Collins on 12-31-12)

Ron, that sure is a nice photo of the gauges working with Dave's software!

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