Lora Wargo Final Project Mixed Techniques

 0. Plan: Originally, my intent was to create an artistic and realistic replica of the “pilot’s six-pack.” However, I left room for improvements and additional aspects to be added, if I had time. I had time upon completing the “pilot’s six-pack,” so I expanded upon my project.

1. Process: 

Pilot Six-Pack

The pilot six-pack, which was the original idea, ended up being the most difficult and time-consuming portion of the project. Originally, I intended to create laser cut faces and attach them. First, I drew the faces. However, Ryan presented the idea of laser cutting my design into an acrylic face and painting it in layers, in order to create a more realistic and layered look. This is the design I ended up doing, but I had a false start. I did not remember that I needed to engrave a mirrored image of my drawing, so I accidentally made six unusable pieces.

I cut the new pieces and painted them. I also cut six clear faces to act as the screen. I wanted to give the instruments and inset look, so I decided to cut six holes into my dashboard in order to attach the faces at the back and the screen at the front. However, I mis-measured the size of the holes, and they ended up being slightly larger than the faces. 

Not wanting to waste the wood, I chose to glue scrap wood to the back of the dashboard. The scrap pieces were then painted with black acrylic. Then, I glued the faces onto the scrap wood in order to hold them in place.

While waiting on various portions of the project’s paint to dry, I laser cut and spray painted needles for the instruments. After gluing the faces onto the scrap wood, I glued the needles to the faces. When I attempted to attach the clear screen over the faces, I found that that circle was also too small for the hole. I laser cut flat rings and painted them black. The intent was to glue them over the holes and attach the screens to the back. This would attach the parts and conceal the gaps at the bottom between the face and the holes. However, I also cut this too small.

 Determined to not allow this to go to waste either, I cut and painted slightly larger rings. I glued both sets of rings to the dashboard with the clear screen behind them, and I am quite happy with the result! Throughout this process some of the acrylic screens became scratched, but I’m happy with the scratches too because they add a worn look to my project that I feel like gives it a “flown-in” feeling. 

Movable Yoke

For the yoke, I wanted the yoke to be able to move in a way that replicates the movement of an actual yoke. It needed to turn counterclockwise and clockwise, as well as be able to be pulled forwards and backwards. I used two PVC pipes to make the movement feasible. The smaller PVC fit inside the first and allowed it to turn. I 3D-printed a piece to fit between the PVCs and allow a snug yet movable fit within the larger PVC. I painted the PVC pipes with black acrylic paint and spray painted a clear scratch-resistant cover over it. 

I created the handles by carving the shape from tactile memory using the sander. I drilled a hole in each of the handles and through the smaller PVC. Then, I sanded down a piece of wood to fit into both handles and through the PVC. I wood stained all the wooden portions.

Then, I glued everything together and onto the board. However, I did not like the visual look of being able to see down the PVC pipe and see the glue I used. To remedy this, I ventured away from my original plan to keep everything as visually accurate as possible. I laser cut a small wooden circle and wood stained it. Then, I painted it with a blue thumbprint heart and the words “Runners” in orange to represent UTSA, which is one of the universities I attend and the one which I feel the most school spirit for. Then, I glued the small wooden token over the PVC mouth in order to conceal the inside.  

Name Plate

The name plate was the quickest and easiest piece I made. I used Adobe Illustrator to create a rectangle with the name “N5145K” on it. The name is the name of an actual plane which I fly regularly at Bulverde Airport, and it is my favorite plane to fly.  I engraved the name and laser cut the rectangle. Then, I glued it to the board. 

Flight Screen

The flight screen was also quite easy to make. I took measurements for what size I wanted it to be and where I wanted to put it. Then, I laser cut a rectangle out of clear, black-painted, acrylic plastic for the screen portion. I also laser cut a rounded rectangle frame and a rectangle backing, and I painted the frame black. I glued everything together and onto the dashboard. 

Movable Throttle

For the throttle, I wanted it to be able to move to replicate how a throttle would actually move. Originally, the design was to have a thick piece of wood with a rectangle carved out of it for the handle to poke through. However, I found the rectangle difficult to cut and the piece to be heavy.

I pivoted to a new design, which was two right triangles of wood, a wooden handle between them, and a wooden cylinder between all three to act as an axle. I made the handle first, which is comprised of three pieces: the handhold, the pike, and the connecting axle. The handhold is an almost cylindrical shape, which I carved using the sander. Then, I carved the pike using the sander. I took a day to stain the wood and let it dry. Then, I drilled a hole into each piece, inserted a small connecting axle, and used wood glue to hold the entire piece together. I also drilled a hole at the end of the pike to slide the axle for the entire piece through. 

For the wooden triangles, I cut them and then sanded the shape down to make it clean and smooth. Then, I drilled a hole through each triangle for the pike to slide through. I wood-stained both pieces and glued the left triangle onto the dashboard. I glued the axle within the pike for the handle. On the last day, I slid the axle into the left and right triangle holds and glued down the right triangle. 

Stand

The stand was the last portion of the project which I added. I wanted the dashboard cockpit to give a similar picture to what you would see from the pilot’s seat, so I chose to have it stand upright. One challenge that I had was a tendency to fall forwards when the yoke was extended due to the weight of the yoke.

I started by taking two pieces of wood. The thicker piece was screwed to the back parallel with the dashboard. The second piece would wedge between the bottom of the first piece and the ground. The second piece kept slipping, so I added a screw on either side of the second piece and drilled two holes through the second piece. I strung a piece of string between the screw and through the hole to keep the second piece from being able to slide too far. However, it was too front-heavy still, so I added another piece of wood to the back to add more weight in the back-leaning direction. The problem was still not fixed, so I added two small feet in the front to prop up the dashboard and prevent it from falling forward. 

2. Result: The end product is a “dashboard cockpit” for a Piper Cherokee. Included on the cockpit is the “pilot’s six-pack,” a movable yoke, a movable throttle, the name of the plane, and an imitation flight screen. The dashboard cockpit has a stand on the back and feet in the front in order to keep it upright and presentable, while also staying stable enough that a user could interact with the yoke and throttle. 

3. Reflection: Looking back, I am glad that I chose an idea which I could easily expand upon and create more aspects for. I am deeply passionate about aviation, so I thoroughly enjoyed this project. There were a few false starts and minor errors throughout, but I am proud of the adaptations I made. I wish I would have been able to add aspects like a co-pilot yoke, the buttons within a cockpit, and make the back-end of the cockpit more visually appealing. However, I think I made much more progress than anticipated, and I think the work is of a decent quality.