The ‘ceiling’ or roof of the cockpit is divided into 3 parts :

  • Front (front ceiling) with folding handles;
  • Eyebrow windows with map lights;
  • Rear (rear ceiling) with attachments and decals.

 

DESCRIPTION

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The ‘rear ceiling’ is the rear section of the cockpithemel that fits in with the ‘Eyebrow windows’.

This rear portion includes the roof section in (almost) white color, equipped with different niches, shutters and panels :

F/O side :

  • Speaker;
  • Lighting ‘Circuit breakers’;
  • Section ‘Emergency escape rope’;
  • ‘Air vent’ grill;
  • Liège ‘Spare Bulbs’.

Capt side :

  • Speaker;
  • Section ‘Emergency escape rope’;
  • ‘Air vent’ grill;
  • ‘Eyeball vent.

The shape and dimensions of the ‘rear ceiling’ is according to your personal measurements in the my cockpit and do not match the real version. So the dimensions of my version are not mentioned.

The objective was the opening behind the ‘Eyebrow windows’ closing and that as much as possible in accordance with the real copy.

Also the views and facilities of the ‘rear ceiling’ varies from type of aircraft. I've noticed that there are various versions ranging from an older B737-800 model, a newer and the NG's. The mounting of the ‘rear ceiling’ is different every time. The cockpitbouwer defines here what he want to follow...

For the dimensions of the various attachments, the panels that are against the ‘rear ceiling’, this is without obtained dimensions. This is done on the ‘estimate’ (guess) and this, after studying various photos of the real versions. Also taking into account according to the personal cockpitsetup.

 

CONSTRUCTION

The construction of the ‘rear ceiling’ was not easy. It is a collection of shapes and contours that are to be. This with a lot of corners, arches and folds all in one piece.

For the ‘rear ceiling’ I aluminum used 1 mm thick. Some cockpitbouwers use wood or forex. Only with wood, or forex, it is not possible angles to folds.

Why corners ?
You can also have a curved sky of wood, forex or aluminium but there are also signs against it are made, and a plane as a whole (the panel), one can not beautiful flush against a curved background. That is why the angles (+ folds) are necessary for flat share to create in the ‘rear ceiling’.

Paper and cardboard

First I have the form, it should determine with the help of paper and cardboard.
I have a number of A3 sheets pasted together and about the ‘Eyebrow windows’ to the outlines or contours of the ‘Eyebrow windows’ from which to draw.

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Then I have this copied on rough cardboard. The card stock I have in one piece fixed to the ‘Eyebrow windows’ and side overhead.

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First, the uitpassing of the ‘Eyebrow windows’ and the side Overhead, this is a good and right start to get.
Rear is not so important. First with what surplus is, with hindsight, one can still understand custom cut.

The difficult part is mainly the outside of the ‘rear ceiling’ (area above the windows). The ‘rear ceiling’make a turn to the bottom, where different folds. This is for mounting on the top of the window frames, the fastening side ‘Eyebrow windows’ and the fastening to the inside of the legs of the cockpitframe.

Therefore, first, the use of paper and cardboard to be very useful. You can to your heart's content to try and test until you got the right form.

Then the cardboard attached at all attachment points such as aluminum (final version) should be done. Afterwards, you can see there are still some shortcomings or mistakes.

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Then one can on the cardboard the various openings to draw such as the opening of the ‘speaker’, the niche of lights ‘circuit breakers’ and possibly of the hatch of the ‘Emergency Escape Rope’.

These openings are of their own choice. I have limited myself to the speaker, alcove lighting ‘circuit breakers’ and a small opening on the panel of the ‘Emergency Escape Rope’. This hatch is ‘dummy’ and should therefore not functioning. The opening is only the black part (handle) "depth".

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Aluminum

I did this with aluminum used 1 mm thick.

Aluminium of 0.5 mm is too thin and 2 mm is too thick. Be sure to plooiwerk. Aluminium of 1 mm provides sufficient rigidity and is easy to bend and to bow.

If the cardboard version meets this copied on a plate. It is advisable to first have a bit more room to take, this can later be custom cut because if everything is too small to fail is it not more correct.

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After the appearance of the shape, openings and plooiwerk for the confirmation, the aluminum panel is already provisionally confirm to see if the connections to the ‘eyebrow windows’ and side Overhead (almost) correct. Here you can also determine where the lines should come up for the different folds in the top (if necessary). This form of flat portions against which the various attachments.

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Folds and corners

To folds and corners to make it in a aluminum plate that I put this between 2 MDF panels so that the drawn plooilijn equal with the both edges of the MDF panels. Everything I put it with 2 sergeants.
Then I take a 3the MDF panel and I press with the flat side on the folding part and this from the edge until the fold is sufficient for the obtained angle.

Attention! An incorrect fold is difficult or not the way to work! Still not ‘home-and-garden-convenience’.

It is then fit and adjust until everything is in the right place and this by using less or more folds. Also by the use of the hacksaw for what's left and right away saw and for fine work is the metaalvijl very useful.

Here, experience has shown that aluminum pretty sharp and so small damage can make to the ‘Eyebrow windows’ and Overhead. Caution is the message.

 

CONFIRMATION

At the front of the ‘rear ceiling’ fixed to the ‘Eyebrow windows’ with 4 bolts 6 mm.

On the Overhead I have on the side and a 3-many L-brackets mounted for the fastening of the cardboard, and later aluminium. These brackets do +- 5 mm above the edge of the overhead.
The fastening is done with bolts, 4 mm.

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On the back I have a aluminium L-profile (25 mm x 25 mm) attached transversely against the metal cockpitframe. First I tapped in the cockpitframe for bolts of 6 mm to which the aluminium is confirmed.
The height of the L-profile (- 5mm)with the bottom of the After Overhead.

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At the bottom of the aluprofiel is the ‘rear ceiling’ fixed with bolts 4 mm.
This back/bottom of the ‘rear ceiling’ continues through to the inside of the buitenbenen of the metal cockpitframe (? – read it again).
Here is a portion of the ‘rear ceiling’ ingeplooid with the same width as the legs of the cockpitframe (50 mm) and then with the sleeve screwed against the frame.

Along the outside is the ‘rear ceiling’ fixed to the top of the window frames.
Also here is a part of the aluminum plate of the ‘rear ceiling’ a 6 cm folded back so that the folded back portion is horizontal and parallel to the top edge of the window frame.
The fastening is done with bolts, 4 mm.

 

CONSTRUCTION F/O SIDE

As already mentioned in the beginning of this chapter are the dimensions of the construction ‘subject to’ and so on ‘estimate’ happened.
The distances between the different attachments, I also tried to match it with the real version.

I have noticed that the setup of the FlyEngravity window frames (with Eyebrow windows) rather wide failure with the result that the ‘rear ceiling’ is also wider and taller. As a result, some of the attachments (panel ‘Emergency Escape Rope’ and panel lighting, Circuit Brackers’) a little further away from each other.

These attachments are, of course, the ‘dummies’ (except the speaker and Circuit breakers lighting’).

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Speaker

The ‘speaker’ in the ‘rear ceiling’ is a built-in loudspeaker and comes from Conrad.be.

The cutout is 77 mm. The total diameter of the entire speaker edge is 100 mm.

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At the place of installation, I first a circle is drawn, and then I did the outline with small holes. Subsequently everything is nicely rounded with a file.

For the confirmation of the speaker, I did have the 4 holes drilled and then wire in the holes tapped. This facilitates the confirmation.

The speaker will later be connected to a mini-amplifier, using a Prosim audio module the correct sounds will have to view.

Panel ‘Circuit breakers’ lighting

The panel of the ‘Circuit breakers’ lighting is made of PVC Foam board 6 mm thick.

PVC Foam is very light and it can also be a bit of folds. So with curves gives the so a little.

The openings are made with a figure and jigsaw, and afterwards nice right made with a file and sandpaper.
The corners are rounded with a file and sandpaper.

PanelCB

 

The confirmation is done with 4 screws (4 mm x 15 mm) on the 4 corners.

Thereafter, the inside of this opening (outside the ‘rear ceiling’) niches with light to be built.

 

Nis ‘Circuit breakers’ lighting

The niches for the light of the ‘circuit breakers’ -lighting, I made out of an empty flea of the Philadelphia-cheese spread.

It is sturdy enough and very light. So easy to paste on the outside of the ‘rear ceiling’.

Just a small hole is made and a light (bulb) at an oblique angle it rotated. The light comes from the Range.

First, I empty the little flea on the inside painted the same color as the ‘rear ceiling’. The outside of the little flea got a black color to light from the outside to prevent.

Then I have the little flea with a lamp with duck tape attached on the top of the opening in the ‘rear ceiling’.

Since I didn't have the ‘Circuit breakers’ have I the light is not connected and serves merely as a "dummy".

By the way this is the kaasvlootje not suitable (too hot). An led lamp.

 

Panel ‘Emergency Escape Rope’

Ditto

The confirmation is done with double-sided tape. This tape I have met in the Street, sticks very well and is, possibly, then it will be easy to remove.

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Panel ‘Spare bulbs’

Ditto

The confirmation is done in part with double-sided tape and the screws of the handle.
Above the handle are also 2 bolts for the fastening. These bolts can also be found in the real version.

The left-hand edge runs parallel with the edge of the ‘Eyebrow Window’.

Panel spare bulbs

Air vent grille (air-Conditioning)

The Air vent grille (grill) is composed of :

  • 1 Plate of MDF of 25 mm;
  • 2 MDF bars of 15 mm x 15 mm;
  • 6 pieces of a plastic angle section of 15 mm x 15 mm (Range or Brico);
  • 1 Rounded triangle aluminiumplaatje (2 mm thickness);
  • 3 countersunk bolts with flat head (4 mm x 25 mm).

The MDF bars of 15 mm be on the top cover glued with wood glue. Afterwards 6 small pieces of the plastic bracket (with superglue) on the inside of the top cover is glued. These small pieces of angle iron to the ribs (fins) proposals of the " Air vent grill.

If this upside-down against the ‘rear ceiling’ hanging one looks only at the top plate with alu-part and the beginning of the fins. That is everything what is visible and what so we need to see ...

The confirmation is done with 4 countersunk bolts 4 mm x 25 mm. These bolts come on the edges of the MDF-bars of 15 mm and top plate and go through the aluminum of the ‘rear ceiling’. The fourth bolt confirms the aluminum triangle, and also goes by the aluplaat of the ‘rear ceiling’.

 

Here is a drawing with the dimensions of the various attachments of an older B737-800 version. These dimensions would be 95% accurate (Note. This drawing I used as a general guide. The dimensions and shapes do not completely match my version).

Roof-Panel2

Thanks to Warren Soeldner for the drawning.

 

 

PAINTINGS

All the parts I painted with a spray can.

First 2 coats of primer and then 2 coats of lacquer.

First, I have the aluminiumgedeelte what sand with abrasive paper grit P320 .

Then everything is degreased with a ontvettingsproduct. For aluminum, this is important.

The primer that I used is a universal primer suitable for all metals, plastics, and is fast drying. This paint is of the brand Südwest – All-Grund (White -9110).

The color of the lacquer was not easy to determine. On photos you can see that it is a white color. But these photos are usually taken with extra lighting (with the flash light) and look so bright white.

View you cockpitfoto's that were taken in daylight and without extra lighting the color is more off-white. The test, you can do so by white parts in the real cockpit to compare with the color of the ‘rear ceiling’. This shows that the clearly broken white.

But in off-white, we have different types such as ‘pearl white’ (RAL1013), ‘cremewit’ (RAL9001), ‘white’ (RAL9003), ‘pure white’ (RAL9010). The correct color is difficult, and depends a little on personal preference.

In these various white colours are there a few pigments and in a dark environment, these colors after a while yellowing. Therefore, I have the color also what whiter taken.

I have chosen ‘White’ (RAL 9016) (GEN.01.86 – ACC Color Map).

This paint is of the brand ‘Sikkens – sikkens rubbol Finura Satin (PU zijdeglanslak low donkervergeling).

The speaker, I also have a paint job. The edge is in RAL9016 and the middle perforated section in Boeinggrijs.

 

DECALS AND AFBOORDLIJSTJES

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The opening of the panel of the ‘Circuit Breakers’-lighting, I have an extra afboordlijstje fitted to the contours of the opening better to make them come true.

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Also on the panel of the ‘Emergency Escape Rope’, I was at the opening, a black afboordlijstje placed out of plastic. The back is closed in depth and gives the appearance of niches for the opening of the (dummy)hatch. The achterzittend niches is also painted black and is on the outside of the ‘rear ceiling’ on the opening pasted with double-sided tape.

The panel of the ‘Emergency Escape Rope’ is further provided with a label with red text.
I did this with the font Tw Cen MT used and this with a font size of 42.

With some airlines we see on this panel also has a sticker with the image of a male is that of a rope climb. That we have there but also included.

The sticker has a size of 45 mm x 54 mm. Printed on photo paper and on the back with double-sided tape. Simple ...

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On the panel of the ‘Spare Bulbs’, I have no stickers used but engraved images.

The white plate with ‘SPARE BULBS’ is created with the font Arial Bold with font size 17 and 7. Size of the plate : 60 mm x 16 mm.

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The yellow plate ‘CAUTION’ and ‘INT713’. is made with the font Arial Bold with font size 22 and 7.
The continuous text is created with font Gill Sans MT Bold with font size 10
Size of the plate : 85 mm x 40 mm.

Gele decal

 

 

 

 

 

 

This yellow decal is found mainly in the Ryanair Boeings.

 

The black handvatje comes from the Range and is made from plastic.

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FINISH ‘REAR CEILING F/O SIDE"

After the painting, the final assembly happen.

First, the aluminum panel and after the confirmation of the attachments. This happens with the bolts for the circuit breaker and bulb spare panels. The ‘Air vent’ grill is also attached with bolts (4).

For the confirmation of the ‘Emergency Escape Rope’ panel and also for additional confirmation of the ‘Bulb Spare panel, I double-sided tape used.

The side edges of the ‘overhead’ and edges against the tubes of the metal cockpitframe I have neatly bordered with afboordstrips.

This afboorden with white strips, one can also see in the real B737 aircraft.

This afboordstrips I met in the Street and they serve to make in a bathroom, a collar between the bath and tiles. They are very smooth and paste well. They are also to be found in the Range.

 

F/O SIDE

 

CPT SIDE

The ‘rear ceiling’ on the CPT side, I using the same concept as F/O side.

Again it is difficult plooiwerk and the bending of the aluminum.

The attachments are :

  • Speaker;
  • Emergency Escape Rope panel;
  • Air vent grille (air-Conditioning);
  • Air vent eyeball (air-Conditioning).

The ‘Air vent eyeball’ I have made according to the same principle as that to be found in my ‘lower panels’ of the MIP.
The niche in the ceiling where the ‘eyeball’ is made from a lid of a plastic jar in which cubes have been sitting. So actually free, and pretty simple to make.

These nis would, in principle, what more to have to figure it out but since my cockpit is not larger is this so difficult :-).

All attachments, on the speaker, are dummies.

 

 

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