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Mission Statement 

The purpose of FLAPS-2-APPROACH is two-fold:  To document the construction of a Boeing 737 flight simulator, and to act as a platform to share aviation-related articles pertaining to the Boeing 737; thereby, providing a source of inspiration and reference to like-minded individuals.

I am not a professional journalist.  Writing for a cross section of readers from differing cultures and languages with varying degrees of technical ability, can at times be challenging. I hope there are not too many spelling and grammatical mistakes.

 

Note:   I have NO affiliation with ANY manufacturer or reseller.  All reviews and content are 'frank and fearless' - I tell it as I see it.  Do not complain if you do not like what you read.

I use the words 'modules & panels' and 'CDU & FMC' interchangeably.  The definition of the acronym 'OEM' is Original Equipment Manufacturer (aka real aicraft part).

 

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Journal Archive (Newest First)
« TaxiSigns HD - Review | Main | Assembly of Forward Overhead Panel »
Tuesday
Sep202016

White Caps for Locking Toggle Switches on Overhead

It has taken a very long time to collect the assortment of OEM needed parts to complete the forward and aft overhead panels.  Finally the build is now in progress and it’s hoped completion will be towards the end of 2016.

LEFT:  Lower electrical panel showing reproduction latex-style cap (ELEC 2) and OEM Honeywell Switch Accessory 15PA90-6W (ELEC 1). Click to enlarge.   For those with keen eyes - yes that is a voice recorder in the lower panel - more to follow in later posts.  Of interest are the two different white caps (read main text). 

Earlier on, I had purchased several dozen Honeywell toggle switches, however, for whatever reason the white caps on the toggles were either missing or damaged.  I was intending to use reproduction white push-on caps (aka white condoms), but the caps failed to  fit snugly to the OEM switches, and their appearance was slightly different to the OEM version - the ends of the caps looked rather bulbous.

My next choice was to use latex caps that are used in automotive industry.  Once again, the appearance was slightly different and the automotive caps sported a small nipple at the end of each cap where they had been connected to the plastic retaining spur; I found the appearance of the nipple disconcerting.

Short of viable options, I purchased the OEM white caps from Honeywell which is the company that supplies Boeing.  If you carefully look at the above picture of the lower electrical panel (click image to enlarge picture), you will observe the nearest toggle switch has been fitted with an automotive style cap; the nipple and joining line is clearly visible.  The second toggle switch is fitted with the Honeywell white cap.

OEM White Cap Anatomy

The reproduction slip-on caps currently available on the market bear little resemblance to those made by Honeywell.

LEFT:   Honeywell Switch Accessory 15PA90-6W showing internal screw thread.  The thread screws onto the stem of the toggle switch (click to enlarge).

Most of the reproduction white caps are either a push-on condom style, or are a white-capped head attached to a slender hollow shaft.  The shaft then slides over the existing switch stem.

The Honeywell caps are not slip-on latex but a solidly-produced head with an internal aluminium thread.  The head is designed to be screwed directly to the shaft of the toggle switches.  Firmly attached to this head is the white latex cap. 

Mounting

To mount the white cap on a toggle, witch you must first gently heat the switch stem which will loosen the head of the toggle.  It then is an easy matter to screw off the head and replace it with the OEM head.

Measurements

Not everyone wants to utilise OEM parts.  As such I have provided the measurements of the switch head (courtesy of Honeywell) for those who wish to try their hand at making their own white caps.

As the overhead build continues, I will be posting more articles that showcase the overhead and the various panels and functionality.

Glossary

Honeywell – Avionics conglomerate that is heavily involved in the defence and aviation industries.
OEM – Original Equipment Manufacture (aka real aircraft part).

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