Build Process

Phase 1 — Research & Dimensioning

Before a single line is cut, accurate dimensions are everything. A wrongly-sized panel slot means a switch doesn't fit, or the legend is off-centre. For the 737 MAX, the primary reference sources were:

• Boeing 737 Technical Training Manual (TTM) — available via training providers
• High-resolution cockpit photography (multiple angles, known reference objects)
• Community-shared measurements from the MyCockpit forums
• Cross-referencing with Level D simulator screenshots

All dimensions are logged in a Fusion 360 spreadsheet (master parameters table) so that changing one value — like glare shield depth — cascades through the whole assembly.

Phase 2 — CAD Design (Fusion 360)

Panel Layout

Each panel is designed as a 2D sketch inside a Fusion 360 component, then extruded to the correct thickness. Cutouts for switches, encoders, annunciators and labels are all parametric.

Key design decisions:

• 3mm MDF for the main panel substrate — cheap, stable, easy to laser cut and paint
• 3mm black acrylic overlay for the legend layer — engraved and backlit through the acrylic
• 1mm white acrylic diffuser behind the legend for even LED illumination

The MCP design alone took approximately 20 hours of CAD work across two weeks.

Exporting DXF Files

Once the sketch is finalized:

1. Right-click the sketch in Fusion 360 browser
2. Save As DXF — this exports all profile curves
3. Clean up in Inkscape (remove duplicates, check line weights)
4. Import to LightBurn for the laser cutter

Phase 3 — Laser Cutting

The laser used for this build is an xTool D1 Pro 20W diode laser. It handles 3mm MDF cleanly in a single pass and engraves acrylic with excellent contrast.

Cut Settings (3mm MDF)

Engraving Settings (3mm Black Acrylic — Legend)

Tip: Always do a test cut on a scrap piece. MDF moisture content and acrylic brands vary significantly — your settings may differ.

Phase 4 — Finishing

Painting

All MDF panels are painted matte black (RAL 9005) with a grey primer base coat:

1. Sand MDF with 180-grit, then 240-grit
2. Apply 2 coats of grey spray primer
3. Light sand with 400-grit wet-and-dry
4. Apply 2–3 coats of matte black lacquer

The acrylic legend overlay is left unpainted — the engraving naturally reveals the white/clear acrylic below the black surface coating.

Panel Assembly

Layers are bonded with M3 standoffs and 3mm bolts, not glue — this allows future disassembly for repairs or modifications.

Panel Stack (front to back):
[Black Acrylic Legend Overlay]   ← 3mm — engraved
[MDF Main Panel]                 ← 3mm — switch cutouts
[1mm White Acrylic Diffuser]     ← 1mm — LED diffusion
[LED Strip PCB / Individual LEDs]
[Rear bracket / mounting plate]

Phase 5 — Electronics Integration

See the Electronics page for full wiring documentation.

The short version:

• Each panel connects to its own ESP32 via a custom wiring harness
• All ESP32s run CockpitConnect firmware and connect to the Bridge over WiFi, with no USB cable to the PC
• The CockpitConnect Bridge on the SimPC runs the Flows that map each input to an X-Plane 12 command

Phase 6 — Software Configuration

CockpitConnect Setup

1. Install the CockpitConnect Bridge on the SimPC, next to X-Plane 12
2. Flash each ESP32 once from the browser on the flash page, then claim it in the app
3. Add each input and output (switch, encoder, button, LED, display) to the board in the Flow Builder
4. Bind each one in a Flow to an X-Plane 12 command or dataref

X-Plane 12 Bindings Used (MCP)

sim/autopilot/servos_toggle                       // AP button
sim/autopilot/heading_up / heading_down           // Heading encoder
sim/autopilot/altitude_up / altitude_down         // Altitude encoder
sim/autopilot/vertical_speed_up / _down           // V/S encoder
sim/autopilot/airspeed_up / airspeed_down         // Speed encoder
sim/cockpit2/autopilot/altitude_dial_ft           // ALT display

Bill of Materials (MCP Only)