The document describes the design and construction of an aviation-themed console to support a flight simulator setup. The console is designed to accurately replicate the positioning of controls found in typical training aircraft like a Cessna 172. It centers the yoke and pedals at the appropriate height for seating and contains all hardware components in a stable but compact footprint that evokes the look of an aircraft fuselage. The console is constructed from oak plywood, wood, and aluminum panels painted in aviation-style colors.

1. Flight Simulator
Desk

2. Objective
Create an aviation themed console to support a flight simulator setup that
reproduces control placement found in typical training aircraft.
Background
The release of a significantly improved Microsoft Flight Simulator in 2020
prompted the desire to enhance its use as a training device by replicating
the positions of the controls within a self-contained console that features a
cool aviation aesthetic.
Design
The design is centered around CH Products computer accessories but
could be adapted for many common brands. Placing the yoke and pedals
at an accurate height relative to the seating position was the primary design
requirement. A Cessna 172 was used for reference dimensions, although
the arrangement is typical of many light general aviation aircraft. The
secondary requirement was to contain all the hardware components within
a stable, but minimally-sized footprint that invoked the appearance of an
aircraft. To improve accessibility, the top shelf is removable. It rests on
shelf pins in the rear panel and thumb screws at the front. Slots in the side
rails accommodate the USB connections and route the cables.
Construction
All of the panels, as well as the front ribs, were cut from ¾” furniture grade
oak plywood. The side ribs, top panel side rails, and accessory shelf front
rail were made from 1½” stock lumber. Countersunk 1¼” wood screws
were used to assemble all components. The side skins were fashioned
from 0.019” thick sheet aluminum panels available at several home
improvement stores. 1/16” holes were drilled at 1” intervals in the metal to
accept the 11mm diameter flat head upholstery tacks used to secure the
panels to the frame. Four adjustable leveling feet were installed in the
bottom panel. The frame was painted with Sherwin Williams 6718 Overt
Green to simulate the zinc-chromate corrosion proofing that is commonly
applied to aircraft fuselages. Rustoleum chalkboard paint was applied to the
top and rear panel to give a matte black finish. 1 of 4
Flight Simulator Desk
Flight Simulator
Desk

3. 2 of 4
Flight Simulator
Desk
Flight Simulator Desk
Suggested cutting template
sized to fit within a 4’x4’ panel
18.5”
23”
24”
Bottom Panel
Front Ribs
1 ½” wide
Yoke shelf
4”
27 ½”
11.8”
16”
23” 24”
16”
Back Panel
Hole
1 ¼” dia
1 ½”
25.5”
25”
15”
40” outer radius
30° arc

4. 3 of 4
Flight Simulator
Desk
Flight Simulator Desk
To fit project within one 4’ x4’ sheet, the top panel can be
accommodated on the previous sheet with careful cutting of the
front ribs. The accessory shelf can be omitted, and the side ribs
and top panel side rails can be made using 1 ½” stock lumber.
Top Panel
~16” x 4 ½“ cutout
16”
17 ¼“
Accessory Shelf
8”
25 ½“
16”
1 ½” side ribs
2”
5”
top panel
side rails
Slot
Accessory
Shelf front
rail
25 ½”

5. 4 of 4
Flight Simulator
Desk
Various view of the Flight
Simulator Console
Flight Simulator Desk