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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.


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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)

Entries in Weber (2)


Installing Weber Pilot Seats to Platform Base

The main instrument panel is an integral part of the flight deck.  Now that it’s installed other components can be fitted to the platform base and measured correctly.  I knew that the two Weber pilot seats would take a considerable amount of time to install, so decided to tackle this job over the weekend.

Attachment Stress

In my earlier posts, I mentioned that to manipulate the various levers which move the seats results in relatively large amount of stress being placed on the attachment points of the seat to the platform floor; there is reason Weber seats have 16 attachment points to the flight deck floor.  To help with the attachment of the seats I incorporated a mount that sits beneath each seat.  The mount, constructed from wood, is 16 mm in thickness and is bolted to the 16 mm thick platform floor (36 mm total thickness).  Rather than use wood screws to attach the seats, I decided to use 55 mm length bolts with washers; my thinking is that the bolts will provide far stronger attachment points, when installed through the seat mounts and platform floor,  than wood screws. 

The Detail

The first task was to cut and paint the seat mounts which was straightforward.  I then positioned each seat on its mounting base and drilled the appropriate holes in the correct position to match the holes in the seat legs.  The seat mounts were then placed on the platform floor in their correct position and the holes drilled through the platform floor.  The platform floor was then removed from the base (note that the platform floor is made of three segments to allow for easy moving if necessary), and each seat was laid on its side to allow placement of the platform floor and seat mount before inserting the bolts and securing the seat.  The platform floor was then positioned back onto the base with the seat attached.  The biggest problem was actually lifting and manoeuvring each seat and its segment of platform floor; together, each seat and segment of flooring weighs over 50 kg.

Correct Positioning

The correct positioning of the seat and seat mount is very important.  Boeing specification states that the distance from the front of the seat to the MIP is 340 mm, however, this depends on where you are measuring to and what type of MIP you are using.  The measurement if using a FDS MIP is from the front of the claw feet to the forward edge of the lower kickstand.  This measurement is 440 cm.

The seats move forward and aft by pivoting over the secured claw feet (see video); therefore, if the measurement is out by a cm or so it is not really an issue as the seat movement can take up the difference. 

It Works….

With the platform floor secured to the base it was time to trial the seats.  Both seats work well and there is no movement or flexing at their attachment points.  There is also no movement where the seat mounts join the platform floor.

I think it was overboard using 16 bolts and bolting through 36 mm of wood!  But, I wanted to make sure the seats did not move on their base as I didn't particularly want to remove them and start over again. 

To see further pictures, navigate to the Image Gallery.

Next on the list is installing the ACE yoke and throttle quadrant.

Note that the wooden platform has been replaced as well as the ACE yoke and 300 series throttle quadrant - new platform installed.


Weber Seat Mechanics - They Are Built To Last

In a earlier journal post (Weber Captain & First Officer Pilot Seats), I discussed the recent addition to the simulator of two Weber pilot seats.  What I didn’t discuss was how these seats actually operate.  Weber seats, although constructed from aircraft rated aluminium are not light in weight; each seat weighs in at approximately 40 kilograms.  Most of the weight is associated with the robustly constructed underside the seat that is rarely seen let alone talked about.

The seat has four movements; vertical rise, forward and aft movement, recline of back rest and under leg rise & fall.  Each movement is controlled by a solid lever on the left hand side of the seat.  Each lever operates a push style button connected to the end of a cable.  As the lever is moved the button is pressed or released with a corresponding press and release from another button at the opposite end of the cable.  This controls the subtle movement of the rear seat recline (like in an automobile) and the under leg rise and fall  of the portion of the seat that can be raised under the calves to allow more or less reach to the rudder pedals).  When the desired position is reached and the lever released a heavy duty ratchet / cog is engaged locking the position in place.

LEFT:  The inner workings of the Weber seat: Heavy duty chassis, the smaller of two springs, two of three cables and the cylindrical hydraulic/pneumatic cylinder.

The two most aggressive aspects of seat movements, is the forward and aft movement and vertical rise of the seat.  Both these movements are used in the Weber design to allow these seats to be used without J-rails.  The aggressive movement is one reason why Weber has designed 16 attachment bolt points in eight claw feet (duck feet) for each seat.

The compression needed to allow these movements is controlled by a very heavily constructed a “sprung” spring that is contained within a cylinder.  This in turn is connected to a hydraulic/pneumatic piston that allows for greater ease in movement.

The seats I’m using are spring and hydraulic controlled.  Weber manufactures a number of different variants: hydraulic, electric, spring or a combination thereof – there are several variations in use throughout aircraft fleets.