In this section you will
see sources for purchasing; actual Boeing 737 cockpit
shells, replications of Boeing 737 cockpit shells, a kit
allowing the simbuilder to construct his own 737 cockpit
shell. Just click on the photos
below for a link to the appropriate supplier of these
shells. Due to the expense involved with these shells, I
decided a better option for me was to use the kit made
by Flight Deck Solutions. I was able to pick up a used
shell from another simbuilder who elected to go with one
of the fiberglass shells pictured below. In addition to
the decreased cost, this option gives me more
flexibility and the enjoyment and challenge of building
my own shell. The FDS shell allows me the option of
finishing the exterior of the shell, or leaving it
uncovered allowing me more time to focus my attention on
the interior of the shell.
My Cockpit Shell
Below is the latest photo
of my cockpit shell. I have modified the FDS shell to
allow the top portion of the shell to be removed in
order to allow easy movement of my simulator in and out
of my garage. This along with other modifications to the
shell will make it easier to move my simulator when we
The shell is almost
complete. I still have to finish around the eyebrows and
add a few more stringers. Next step for the shell is to
cover it with fiberglass. That will have to wait until I
finish the platform as well as the main instrument panel
and glare shield. I want to fit them to the shell before
I cover it. Click on
the photo of my shell below for a direct link to the
supplier of this kit. I will post additional photos as I
complete the shell.
I couldn't resist taking
a few photos with my new seats in the cockpit. It is
beginning to feel like a simulator. Well, at least I can
dream about it!
That covered pile you see
through the windshield is all of the stuff I have
accumulated over the past six months getting ready to
build my sim. It includes flight controls, rudder pedal
assemblies, another set of aircraft seats, and various
other used aircraft parts to make my simulator as
realistic as possible. At some point I will pull all of
this out and add pictures of it to the accessories page
of my website.
Here I am beginning to
add the ribs on the top section of the shell.
I was having a little
trouble figuring out how to line up the ribs on the top
of the shell. I decided to add supports in the overhead
to support the overhead panels, and this made it much
easier to add the ribs.
I wanted you to be able
to see how well the eyebrows from an actual Boeing
aircraft fit if the nose sectional from Flight Deck
Solutions. Way to go Peter and his team for such an
Here I have completed the
windshield and am ready to begin on the overhead of the
shell. I am sure this will be a challenge, especially
trying to fit the eyebrow frames around the eyebrows
themselves. I will probably save that task until the
With the front of the
windshield in and the left side almost completed I am
now ready to work on the right side of the windshield.
The windshield has been the hardest part of this project
yet. Now that I have worked out the angles on the left
side I hope the right side will go faster.
Working on the windshield
frame on the left side of the shell.
With the front part of
the windshield in I now have a focal point to work from.
Note the 2x4's I am using to make sure my windshield is
level. This proved to be very beneficial in supporting
the windshield as I was securing it to the rest of the
I have designed the
windshield to split down the middle to facilitate taking
the shell apart for moving my simulator. In addition to
the split down the middle, it also splits apart where
the top of the windshield joins to the overhead of
the shell. This will enable me to separate my shell into
four separate pieces. In addition to allowing me to
break it down for moving, this design will allow me to
make a convertible out of my cockpit to give easier
access during construction of my sim.
Here I am checking the
fit of the eyebrows and overhead panel along with a few
trim panels to see that the angles fit properly. I used
the windshield frames from the Flight Deck Solutions kit
as templates to cut out the boards for my windshield. I
made no modifications to the length or angles of the
templates although I did make the boards wider than the
templates. Everything fit together beautifully.
Though not yet complete I
am having a lot of fun building this kit. It is
challenging enough to hold my interest, yet not so
difficult as to prevent me from completing it.
I have ordered an actual
cockpit door from a 737 to fit into my sim. Here I am
adding a frame so I will be able to mount the door. In
addition it will provide added structural support. I
also added supports at the floor for mounting on the
platform. Though not completed yet, I will be making
horizontal cuts on the back wall at the top level of the
windshield that will allow me to take the top of the
This is what I have
completed after two days of work.
Fabricated Cockpit Shells
Click on the photos below
for direct links to the suppliers of these fabricated
737 cockpit shells. There may be other companies
presently producing these shells, however as of 1/23/06
these are the only ones that I am familiar with.
For some builders,
nothing but the real thing will do for their simulator.
Click on the logos or address below for direct links to
some suppliers of actual cockpit shells.