[{"data":1,"prerenderedAt":635},["ShallowReactive",2],{"article-737max-build-process":3},{"id":4,"title":5,"body":6,"description":624,"downloads":625,"extension":626,"lastUpdated":627,"meta":628,"navigation":629,"path":630,"readingTime":631,"seo":632,"stem":633,"__hash__":634},"projectArticles\u002Fprojects\u002F737max\u002Fbuild-process.md","Build Process",{"type":7,"value":8,"toc":602},"minimark",[9,14,18,41,44,50,53,57,62,70,73,93,96,100,103,129,134,136,140,147,151,211,215,264,273,277,280,291,293,296,298,302,306,313,327,330,334,345,356,358,362,370,373,392,394,398,402,424,428,473,475,479,598],[10,11,13],"h2",{"id":12},"phase-1-research-dimensioning","Phase 1 — Research & Dimensioning",[15,16,17],"p",{},"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:",[19,20,21,25,28,38],"ul",{},[22,23,24],"li",{},"Boeing 737 Technical Training Manual (TTM) — available via training providers",[22,26,27],{},"High-resolution cockpit photography (multiple angles, known reference objects)",[22,29,30,31],{},"Community-shared measurements from ",[32,33,37],"a",{"href":34,"rel":35},"https:\u002F\u002Fmycockpit.org",[36],"nofollow","the MyCockpit forums",[22,39,40],{},"Cross-referencing with Level D simulator screenshots",[15,42,43],{},"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.",[45,46],"content-image",{"alt":47,"caption":48,"src":49},"Fusion 360 parameters table","Master parameters table in Fusion 360 — every critical dimension driven by a variable","\u002Fimages\u002Ffusion360-params.jpg",[51,52],"hr",{},[10,54,56],{"id":55},"phase-2-cad-design-fusion-360","Phase 2 — CAD Design (Fusion 360)",[58,59,61],"h3",{"id":60},"panel-layout","Panel Layout",[15,63,64,65,69],{},"Each panel is designed as a ",[66,67,68],"strong",{},"2D sketch"," inside a Fusion 360 component, then extruded to the correct thickness. Cutouts for switches, encoders, annunciators and labels are all parametric.",[15,71,72],{},"Key design decisions:",[19,74,75,81,87],{},[22,76,77,80],{},[66,78,79],{},"3mm MDF"," for the main panel substrate — cheap, stable, easy to laser cut and paint",[22,82,83,86],{},[66,84,85],{},"3mm black acrylic"," overlay for the legend layer — engraved and backlit through the acrylic",[22,88,89,92],{},[66,90,91],{},"1mm white acrylic"," diffuser behind the legend for even LED illumination",[15,94,95],{},"The MCP design alone took approximately 20 hours of CAD work across two weeks.",[58,97,99],{"id":98},"exporting-dxf-files","Exporting DXF Files",[15,101,102],{},"Once the sketch is finalized:",[104,105,106,109,115,122],"ol",{},[22,107,108],{},"Right-click the sketch in Fusion 360 browser",[22,110,111,114],{},[66,112,113],{},"Save As DXF"," — this exports all profile curves",[22,116,117,118,121],{},"Clean up in ",[66,119,120],{},"Inkscape"," (remove duplicates, check line weights)",[22,123,124,125,128],{},"Import to ",[66,126,127],{},"LightBurn"," for the laser cutter",[45,130],{"alt":131,"caption":132,"src":133},"MCP DXF in LightBurn","MCP DXF file loaded in LightBurn, ready to cut","\u002Fimages\u002Fmcp-dxf.jpg",[51,135],{},[10,137,139],{"id":138},"phase-3-laser-cutting","Phase 3 — Laser Cutting",[15,141,142,143,146],{},"The laser used for this build is an ",[66,144,145],{},"xTool D1 Pro 20W"," diode laser. It handles 3mm MDF cleanly in a single pass and engraves acrylic with excellent contrast.",[58,148,150],{"id":149},"cut-settings-3mm-mdf","Cut Settings (3mm MDF)",[152,153,154,167],"table",{},[155,156,157],"thead",{},[158,159,160,164],"tr",{},[161,162,163],"th",{},"Setting",[161,165,166],{},"Value",[168,169,170,179,187,195,203],"tbody",{},[158,171,172,176],{},[173,174,175],"td",{},"Power",[173,177,178],{},"90%",[158,180,181,184],{},[173,182,183],{},"Speed",[173,185,186],{},"300 mm\u002Fmin",[158,188,189,192],{},[173,190,191],{},"Passes",[173,193,194],{},"1",[158,196,197,200],{},[173,198,199],{},"Focus",[173,201,202],{},"Manual, material surface",[158,204,205,208],{},[173,206,207],{},"Air assist",[173,209,210],{},"On",[58,212,214],{"id":213},"engraving-settings-3mm-black-acrylic-legend","Engraving Settings (3mm Black Acrylic — Legend)",[152,216,217,225],{},[155,218,219],{},[158,220,221,223],{},[161,222,163],{},[161,224,166],{},[168,226,227,234,241,249,257],{},[158,228,229,231],{},[173,230,175],{},[173,232,233],{},"55%",[158,235,236,238],{},[173,237,183],{},[173,239,240],{},"4000 mm\u002Fmin",[158,242,243,246],{},[173,244,245],{},"DPI",[173,247,248],{},"318",[158,250,251,254],{},[173,252,253],{},"Mode",[173,255,256],{},"Bidirectional",[158,258,259,261],{},[173,260,207],{},[173,262,263],{},"Off",[265,266,267],"blockquote",{},[15,268,269,272],{},[66,270,271],{},"Tip:"," Always do a test cut on a scrap piece. MDF moisture content and acrylic brands vary significantly — your settings may differ.",[10,274,276],{"id":275},"content-gallery","::content-gallery",[15,278,279],{},"images:",[19,281,282,285,288],{},[22,283,284],{},"src: \u002Fimages\u002Flaser-cutting.jpg\nalt: Laser cutting MDF panel\ncaption: \"Cutting the MCP substrate on the xTool D1 Pro\"",[22,286,287],{},"src: \u002Fimages\u002Fengraved-acrylic.jpg\nalt: Engraved acrylic legend plate\ncaption: \"Engraved black acrylic overlay — legends glow white when backlit\"",[22,289,290],{},"src: \u002Fimages\u002Fpanel-test-fit.jpg\nalt: Test fitting panel pieces\ncaption: \"First test fit of MCP layers before painting\"",[51,292],{},[15,294,295],{},"::",[51,297],{},[10,299,301],{"id":300},"phase-4-finishing","Phase 4 — Finishing",[58,303,305],{"id":304},"painting","Painting",[15,307,308,309,312],{},"All MDF panels are painted ",[66,310,311],{},"matte black"," (RAL 9005) with a grey primer base coat:",[104,314,315,318,321,324],{},[22,316,317],{},"Sand MDF with 180-grit, then 240-grit",[22,319,320],{},"Apply 2 coats of grey spray primer",[22,322,323],{},"Light sand with 400-grit wet-and-dry",[22,325,326],{},"Apply 2–3 coats of matte black lacquer",[15,328,329],{},"The acrylic legend overlay is left unpainted — the engraving naturally reveals the white\u002Fclear acrylic below the black surface coating.",[58,331,333],{"id":332},"panel-assembly","Panel Assembly",[15,335,336,337,340,341,344],{},"Layers are bonded with ",[66,338,339],{},"M3 standoffs"," and ",[66,342,343],{},"3mm bolts",", not glue — this allows future disassembly for repairs or modifications.",[346,347,352],"pre",{"className":348,"code":350,"language":351},[349],"language-text","Panel Stack (front to back):\n[Black Acrylic Legend Overlay]   ← 3mm — engraved\n[MDF Main Panel]                 ← 3mm — switch cutouts\n[1mm White Acrylic Diffuser]     ← 1mm — LED diffusion\n[LED Strip PCB \u002F Individual LEDs]\n[Rear bracket \u002F mounting plate]\n","text",[353,354,350],"code",{"__ignoreMap":355},"",[51,357],{},[10,359,361],{"id":360},"phase-5-electronics-integration","Phase 5 — Electronics Integration",[15,363,364,365,369],{},"See the ",[32,366,368],{"href":367},"\u002Fprojects\u002F737max\u002Felectronics","Electronics page"," for full wiring documentation.",[15,371,372],{},"The short version:",[19,374,375,382,389],{},[22,376,377,378,381],{},"Each panel connects to an ",[66,379,380],{},"Arduino Mega 2560"," via a custom wiring harness",[22,383,384,385,388],{},"All Arduinos run ",[66,386,387],{},"MobiFlight firmware"," and appear as USB HID devices",[22,390,391],{},"MobiFlight Connector on the PC maps each input to a SimConnect event",[51,393],{},[10,395,397],{"id":396},"phase-6-software-configuration","Phase 6 — Software Configuration",[58,399,401],{"id":400},"mobiflight-setup","MobiFlight Setup",[104,403,404,412,415,418],{},[22,405,406,407],{},"Install ",[32,408,411],{"href":409,"rel":410},"https:\u002F\u002Fwww.mobiflight.com",[36],"MobiFlight Connector",[22,413,414],{},"Flash each Arduino Mega with MobiFlight firmware via the Connector app",[22,416,417],{},"Define each input (switch, encoder, button) in the MobiFlight device config",[22,419,420,421],{},"Map each input to a MSFS SimConnect variable or event in the ",[66,422,423],{},"Output\u002FInput Config",[58,425,427],{"id":426},"simconnect-variables-used-mcp","SimConnect Variables Used (MCP)",[346,429,433],{"className":430,"code":431,"language":432,"meta":355,"style":355},"language-cpp shiki shiki-themes github-light github-dark","\u002F\u002F Example SimConnect events mapped from MobiFlight\nAUTOPILOT_AP_MASTER              \u002F\u002F AP Master switch\nAUTOPILOT_HEADING_BUG_SET        \u002F\u002F Heading encoder\nAUTOPILOT_ALTITUDE_SLOT1_SET     \u002F\u002F Altitude encoder\nAUTOPILOT_VERTICAL_SPEED_SET     \u002F\u002F V\u002FS encoder\nAUTOPILOT_AIRSPEED_HOLD_VAR_SET  \u002F\u002F Speed encoder\n","cpp",[353,434,435,443,449,455,461,467],{"__ignoreMap":355},[436,437,440],"span",{"class":438,"line":439},"line",1,[436,441,442],{},"\u002F\u002F Example SimConnect events mapped from MobiFlight\n",[436,444,446],{"class":438,"line":445},2,[436,447,448],{},"AUTOPILOT_AP_MASTER              \u002F\u002F AP Master switch\n",[436,450,452],{"class":438,"line":451},3,[436,453,454],{},"AUTOPILOT_HEADING_BUG_SET        \u002F\u002F Heading encoder\n",[436,456,458],{"class":438,"line":457},4,[436,459,460],{},"AUTOPILOT_ALTITUDE_SLOT1_SET     \u002F\u002F Altitude encoder\n",[436,462,464],{"class":438,"line":463},5,[436,465,466],{},"AUTOPILOT_VERTICAL_SPEED_SET     \u002F\u002F V\u002FS encoder\n",[436,468,470],{"class":438,"line":469},6,[436,471,472],{},"AUTOPILOT_AIRSPEED_HOLD_VAR_SET  \u002F\u002F Speed encoder\n",[51,474],{},[10,476,478],{"id":477},"bill-of-materials-mcp-only","Bill of Materials (MCP Only)",[152,480,481,494],{},[155,482,483],{},[158,484,485,488,491],{},[161,486,487],{},"Item",[161,489,490],{},"Qty",[161,492,493],{},"Source",[168,495,496,505,516,527,538,548,558,569,579,589],{},[158,497,498,500,502],{},[173,499,380],{},[173,501,194],{},[173,503,504],{},"AliExpress",[158,506,507,510,513],{},[173,508,509],{},"Taiway ON-OFF-ON toggle switch",[173,511,512],{},"8",[173,514,515],{},"Leobodnar",[158,517,518,521,524],{},[173,519,520],{},"Bourns PEC11R encoder",[173,522,523],{},"6",[173,525,526],{},"Mouser",[158,528,529,532,535],{},[173,530,531],{},"3mm MDF sheet (600×400mm)",[173,533,534],{},"2",[173,536,537],{},"Local timber",[158,539,540,543,545],{},[173,541,542],{},"3mm black acrylic (600×400mm)",[173,544,194],{},[173,546,547],{},"Online",[158,549,550,553,556],{},[173,551,552],{},"WS2812B LED strip (60\u002Fm)",[173,554,555],{},"1m",[173,557,504],{},[158,559,560,563,566],{},[173,561,562],{},"M3×6 bolts",[173,564,565],{},"40",[173,567,568],{},"Local",[158,570,571,574,577],{},[173,572,573],{},"M3 brass standoffs (5mm)",[173,575,576],{},"20",[173,578,504],{},[158,580,581,584,586],{},[173,582,583],{},"Grey primer spray",[173,585,194],{},[173,587,588],{},"Hardware store",[158,590,591,594,596],{},[173,592,593],{},"Matte black lacquer",[173,595,194],{},[173,597,588],{},[599,600,601],"style",{},"html .default .shiki span {color: var(--shiki-default);background: var(--shiki-default-bg);font-style: var(--shiki-default-font-style);font-weight: var(--shiki-default-font-weight);text-decoration: var(--shiki-default-text-decoration);}html .shiki span {color: var(--shiki-default);background: var(--shiki-default-bg);font-style: var(--shiki-default-font-style);font-weight: var(--shiki-default-font-weight);text-decoration: var(--shiki-default-text-decoration);}html .dark .shiki span {color: var(--shiki-dark);background: var(--shiki-dark-bg);font-style: var(--shiki-dark-font-style);font-weight: var(--shiki-dark-font-weight);text-decoration: var(--shiki-dark-text-decoration);}html.dark .shiki span {color: var(--shiki-dark);background: var(--shiki-dark-bg);font-style: var(--shiki-dark-font-style);font-weight: var(--shiki-dark-font-weight);text-decoration: var(--shiki-dark-text-decoration);}",{"title":355,"searchDepth":445,"depth":445,"links":603},[604,605,609,613,614,618,619,623],{"id":12,"depth":445,"text":13},{"id":55,"depth":445,"text":56,"children":606},[607,608],{"id":60,"depth":451,"text":61},{"id":98,"depth":451,"text":99},{"id":138,"depth":445,"text":139,"children":610},[611,612],{"id":149,"depth":451,"text":150},{"id":213,"depth":451,"text":214},{"id":275,"depth":445,"text":276},{"id":300,"depth":445,"text":301,"children":615},[616,617],{"id":304,"depth":451,"text":305},{"id":332,"depth":451,"text":333},{"id":360,"depth":445,"text":361},{"id":396,"depth":445,"text":397,"children":620},[621,622],{"id":400,"depth":451,"text":401},{"id":426,"depth":451,"text":427},{"id":477,"depth":445,"text":478},"Step-by-step construction log for the Boeing 737 MAX cockpit — from first sketches in Fusion 360 to a fully wired, backlit panel.",null,"md","2026-03",{},true,"\u002Fprojects\u002F737max\u002Fbuild-process",12,{"title":5,"description":624},"projects\u002F737max\u002Fbuild-process","C4oL4cjV8c0iCtuoJ0JaltQvsPQlNmOpnNOhup8QurE",1781294860551]