The

Akers-Barnes Cockpit, Mark 1

Revision 1.6f (metric and imperial)

Thank you for your interest Flying Furniture’s Akers-Barnes Cockpit, Mark 1.

The Akers-Barnes Cockpit, Mark 1 (ABC Mk1) is designed as a light weight, portable and easy to build cockpit for the

computer flight simulation enthusiast. The key element of the design is its simplicity of construction; requiring only

some flat sheets of plywood and a saw, with no nails, screws, glue or dowels. This simplicity also makes the cockpit

highly portable – it can be put together and taken apart in a matter of minutes, and will easily fit in the boot (trunk) of

even a small car. The cockpit is also adaptable, and can be adjusted to suit people of different heights and builds.

Legalese  
This design is Copyright Ó Peter Akers and Michael Barnes, 1999.  All rights reserved.
Permission to utilise this design to construct a cockpit, or to adapt this design to another application, must be

obtained in writing or e-mail from Peter Akers or Michael Barnes. W e apologise for this requirement, but we wish to

retain the rights to this design should we ever intend to go into commercial production. In order to retain those rights,

we can only allow the design to be utilised under license.

However, we are happy to grant license to members of the on-line flight simulation community who would like to use

our design to construct a cockpit for their personal use, provided you contact us for permission. We do not charge

for use of the design, though donations are gratefully accepted. If you obtained this document from a friend, and

would like to use the design, please contact us at the e-mail addresses below.

For permission to utilise the design for commercial production, please contact us for licensing arrangements.

Contact Information

Flying Furniture flyingfurniture@powerup.com.au

Michael Barnes michael.barnes@intellection.com.au

127 College Road, Karana Downs, 4306, Queensland, Australia.

Peter Akers akersp@ozemail.com.au

You can also find this information, and the latest version of this document, at the 62nd Fighting Falcons web site:

http://www.62ndfightingfalcons.asn.au/

Disclaimer

Peter Akers and Michael Barnes take no responsibility for injury to person or property that arises during the

construction or use of the cockpit described here. You must use your own judgement as to the quality of materials

and workmanship required, and your own competence to undertake the construction.

The Flying Furniture ABC Mk 1

Copyright Ó Peter Akers and Michael Barnes, 1999. All Rights Reserved

Page 1
Construction

The process of constructing the ABC Mk1 is very simple:

1. Mark out the pieces on a sheet or sheets of plywood, using the dimensioned plans below for sizes. The actual

layout of the pieces will depend on the size of the plywood sheets you use.

2. Cut out the pieces

That’s it – your cockpit is now ready to use! It couldn’t get much simpler than that, could it?

Of course, there is still finishing to do, should you want to:

3. Fill any chips and nicks along the cut edges

4. Sand all of the cut edges smooth

5. Paint all of the pieces

6. Cut out and cover a foam cushion for the seat.

7. Add any clips, hooks or Velcro strips you require to attach your keyboard and joysticks.  

Materials
The materials required are:  
Metric Version (See Figure 2a)  Imperial Version (See Figure 2b)
· 6 x 900x1200 sheets of 12mm thick 5 ply plywood · 6 x 3ft x 4ft sheets of 1/2 inch thick 5 ply plywood (A-

(A-B grade or higher quality) or, B grade or higher quality) or,

2 x 1200x2400 sheets of 12mm thick 5 ply plywood 2 x 4ft x 8ft sheets of 1/2 inch thick 5 ply plywood (A-

(A-B grade or higher quality) B grade or higher quality)

You can use different sized sheets, but you will need You can use different sized sheets, but you will need

a minimum dimension of 1100mm for the largest a minimum dimension of 43 1/4 inches for the largest

pieces. pieces.

· 550mm of 24mm diameter steel pipe, or equivalent · 20 inch long, 1 inch diameter steel pipe, or

diameter wooden rod. equivalent diameter wooden rod.

Foam rubber for the seat. 75mm thickness is Foam rubber for the seat. 3 inch thickness is

recommended, the denser the better. You will need recommended, the denser the better. You will need

450x550 for the seat, 450x815 for the back, plus an 15 3/4 x 17 1/2 for the seat, 17 1/2 x 25 1/2 for the back,

additional 240x210 if you want a double thickness on the plus an additional 9 1/2 x 8 if you want a double

headrest. thickness on the headrest.  

Equipment
We have found the following equipment to be helpful when constructing a cockpit:

· A pencil

· A straightedge, 1m (3ft) long

· A tape measure

· A circular saw for the long cuts

· A jigsaw for the notches and fiddly bits

· A rasp, for adjusting the fit of the notches.

· A pair of sawhorses or suitable workbench

 ABC Mk 1
The Flying Furniture Copyrigh t Ó Peter Akers and Michael Barnes, 1999. All Rights Reserved Pag e 2
Notes  

Notes for Metric Version only
· The plans are designed for 12mm thick ply. If you use a different thickness of plywood you will need to adjust

the widths and positions of all the slots and the height of the tabs accordingly. To assist with this, use the red

lines in figure 3.

· It is useful to have the slots on parts (A) and (D) (only) to be a few millimetres closer to the centre of the cockpit

(horizontally as they appear in figure 3). This is so that they fit tightly and lock into place.

Note: The plans already have them shown as .25cm closer than might be expected. You do NOT need to adjust

these measurements to make the fit tight.  

Notes for Imperial Version only
· The plans are designed for 1/2 inch thick ply. If you use a different thickness of plywood you will need to adjust

the widths and positions of all the slots and the height of the tabs accordingly. To assist with this, use the red

lines in figure 3.

· Unlike the metric version, the all the slots and cut-outs are drawn at exactly the same as the thickness of the

timber sheets (1/2 inch). They really should be about 9/16 inch. As a result, it is important that you cut the slots

and cut-outs just slightly on the outside of the lines as you mark them on the wood. If you don’t the pieces will all

be a very tight fit.

· It is useful to have the slots on parts (A) and (D) (only) to be a few millimetres closer to the centre of the cockpit

(horizontally as they appear in figure 3). This is so that they fit tightly and lock into place.

Note: The plans already have them shown as 1/4 inch closer than might be expected. You do NOT need to

adjust these measurements to make the fit tight.  

Notes for Both Versions
· The dimensions for the metric and imperial versions are not interchangeable. Use only one version for all

measurements.

· W e have found that use plywood produces the strongest and best results, but may people have successfully

used Medium Density Fibreboard (MDF).

NOTE: If you use MDF, care should be taken to avoid breathing in the dust while cutting.

· Figure 3 is included to use as a reference when marking the wood before cutting. Most of the measurements in

the cockpit are fairly flexible. However, the red lines indicate those slots and tabs that  must line up.
· There are several possible positions for the seat included in the plan. You can vary this further by changing the

dimensions of the relevant pieces:

1. The forward holes in parts (N) and (O), and the full size version of part (G) are used in conjunction with

putting part H in the forward seat slot. This gives a fairly upright seat position, closer to the monitor screen

and front panel.

2. The rearward alternate, holes in parts (N) and (O), and the cut down part (G) are used in conjunction with

part I in the forward seat position. This seat position is well suited for taller people or if you prefer a greater

inclination of the seat back. The inclination this gives is closer to that found in a real F-16’s cockpit.

· You will probably want to trim the height of the front console to suit the size and position of your monitor. This

will vary depending on your hardware, and whether you have a desktop case under the monitor or a tower case

beside the console. W e have also found that sloping the ‘shoulders’ of the front panel as indicated on the plans

produces a more attractive result.

· The two notches on each side of the foot well area of the part (A) design to accept parts (P) and (Q) (the steering

wheel and keyboard trays) will probably be too tight and will need to be reshaped slightly with a file or rasp. The

top back, and bottom front of each notch (as seen from the front when the desk section is fully assembled) will to

be shaved. This will only be obvious when you put the tray parts into the notches and through to the cut-outs in

part (B).

· W e have found that building a small ‘wedge’ out of the scrap timber, to tilt your joystick forward about 20

degrees, makes it more comfortable to use in a ‘sidestick’ position.

· Parts (H), (I), (J) and (K) have alternate dimensions marked which allow for wider seat side shelves (strakes).

These alternate dimensions should be used if you have a wide based joystick and/or throttle (wider than the

earlier Thrustmaster FLCS+TQS combination). Technically, the standard dimensions are suitable for the

Thrustmaster HOTAS Cougar, however they are a fairly tight fit and you may prefer the extra space of the wider

version.

 ABC Mk 1
The Flying Furniture Copyrigh t Ó Peter Akers and Michael Barnes, 1999. All Rights Reserved Pag e 3
· W e have no specific recommendations for making the seat cushions. Many different approaches have been

used with varying success.

The original cockpits used 7.5cm (3 inch) thick foam rubber with a variety of coverings, including home mage,

professionally upholstered, and a lycra car seat cover.

The foam proved suitable for the back but it was too soft for the seat so we added a 1.5cm high density foam

rubber mat under the seat cushion. A suitable material would be the stuff they use for camping/hiking sleeping

mats, which can be purchased very cheaply at camping/outdoor stores.

W e would recommend that you design the seat cushion with extra padding for your lower back.

Headrests. Don't follow my wedge shaped design (which is seen in many of the photos). It doesn't support your

neck well. Michael's design is quite good. It is two 10cm slabs put together with a 45degree slice taken out of the

lower edge of the top slab. 

Figure 1: The assembled cockpit

 ABC Mk 1
The Flying Furniture Copyrigh t Ó Peter Akers and Michael Barnes, 1999. All Rights Reserved Pag e 4
Plans

4.7 8
17.1 All dimensions are in Centimetres (cm)

1
11.95 41

4.1
2.9 20
66
11.95

4.1

11
6.2
cut to suit YOUR monitor size

3 .11
9

4.9
10.6 g

13
c d

8
aa ab
B G x

9 .82
w
A

02
01
aa ab 10 aa

9 .84
a

8 .84
15

4.7 10.1 10 Q D h
45
5.2

10.2 1.3 9.9

1.3

6 .72

01
10.1
1. 42

10 ab 4.7
NOTE: Apart from the cutouts in the centre of piece B,

16.4 pieces B & C are identical!

01
15.4

4.9
ie. All external dimensions are identical. 10
.3
1
9.3

66
4.2

1.3
36 54
1.3 10
4.25

01
1.3 1.3 1.3
4.25
e f

1
2 10

02
C 4.7 4.7

0
19 45 36 h

01
49 25

1
0
53.5 54 b
11 f d

3.1
13.7
4.7 1.3

4.9
83

draobyek RUOY tius ot tuC

tis lliw d raobyek ehT .ezis

aa
NOTE: Pieces E & F are NOT identical!
E
83.6 The notches on the top of the two pieces
45

2
are positioned differently.
13 If making alternate size, 5 19.7

8 .83

8 .84
21 P All other dimensions are the same.

01

.pag eht ssorca

remove these blocks

47.6 12 12
45
ab
3
7 .32
52

5 .91

4.9

7.6
H  
3.1
5 .21

j k 28
42 50.3

17 17.7
10
10
1.3 11 1.3
9 46

3
65.6 10 10
NOTE: this is the only NOTE: Pieces H & I are NOT identical!
g

5.2
different dimension in The hight of the center piece is different.
pieces H & I
93.6

3.1
x e c
5 If making alternate size, a
69

18
remove these blocks 82

1
5
L 2.5

9.
56

85
m p

01
27

06
q r F
N
5 .61

n o
I

03
ok Ø2.4 k o

7 .32
7 .32

03
Ø2.4

75.6
9 9

u v 63.5 5.1
7

110 30
1.3 1.3 70
5 5 66.1
9 9
6.3 110
9 9
q r
3 .42

9
3 .91

10
p J

01
45 NOTE: Pieces N & O are identical
5.2

8 Akers-Barnes Cockpit - Mark 1

5

NOTE: Pieces J & K are identical

w
100 1.3 revision 1.6.1
5.1
04

M Timber 12mm 5ply Plywood or better

2

Other Materials 1 x 50cm 2.4cm dameter steel tube (or wood rod)
05

s t
s t
O
81

Copyright Peter Akers & Michael Barnes 1999

K
3

m
3.1

All right reserved

n Ø2.4
3.1

v u j j n
3.1

Permission to utilise this design to construct a cockpit, or to adapt

Ø2.4
5 .21

this design to another application, must be obtained in writing or

30 63.5
8

e-mail from either:  

5
1.3 1.3
9 9 Michael Barnes  Peter Akers. 
5

31.3 13.9 3 44
9 9 michael.barnes@intellection.com.au  akersp@ozemail.com.au 
50
15.2 9

Figure 2a: The pieces required and their dimensions

The Flying Furniture  ABC Mk 1 Copyright Ó Peter Akers and Michael Barnes, 1999. All Rights Reserved Page 5
 1 3/4
All dimensions are in inches

4/ 1 4
22
19 1/2
18 1/4 15 1/2
6 3/4 26
26
17
1 3/4

4/3 1
cut to suit YOUR monitor size
7 4 7 1 3/4

2/ 1
4
4

2/1

21
g x

2/1 11

4/3 7
A w G

4
aa
6

c aa ab d

4
B

2/1 91

1
4
a b
2/1 3

2/1 91

2/1 91
02

aa ab

4/3 3
2/1 61

4/1 1
4
Q
D

2/1 4
4

4/1 3
h 1/2
1/2
1

17 1/2

2/1 9

4
21 1/2 ab

4
11
2/1 6

1 3/4
1 3/4

6
1

1
2/1 1

4
NOTE: Apart from the cutouts in the centre of piece B,

1
pieces B & C are identical!
1/2 4
1 3/4 ie. All external dimensions are identical. 1 1/4 1/2
1/2 1/2
3/4 1/2 4 4
26 14 1/4 21 1/2
7 1/2 4 7

4/3 3

4
18
h
19 1/2 e f

8
21 3/4 C

4
18 1/4
10 f d b

2/1
33
4 1/4
1 3/4 4

2/1 32
NOTE: Pieces E & F are NOT identical!
32 1/2
2/1

The notches on the top of the two pieces

17 1/2
are positioned differently.
E
18 1/2
8 All other dimensions are the same.

draobyek RUOY tius ot tuC

7

tis lliw d raobyek ehT .ezis

If making alternate size,
4 3/4 4 3/4

4
5 remove these blocks
2
1/2

4/1 1
2/1 51

2/1 91
/2

4/3 3
1

.pag eht ssorca

17 1/2

4
i l

4/ 3
4/ 3 9

4/1 9
4/3 7

4/3 2
H 7 3/4
2/1

j k 20
5

11 1/2
1/2
1/2 6 3/4
3 1/2 3 1/2 1 1/4 4 4
4 1/4
25 1/2 4 7
14 1/4
NOTE: this is the only NOTE: Pieces H & I are NOT identical!
g
4/3 73

4/3 3
different dimension in The hight of the center piece is different.
pieces H & I
36 1/2

4/3 11
1
2/1 52
x c

2/1

4/1 01
9 L e a

1
If making alternate size,
4/1 82

remove these blocks

7 32 1/4
2
31 1/4

4/3 22
1

2/1 32
m p

4/3 2

42
02
q r F
N
2/1 6

4/3 11
n o
I

4/1 9

4/1 9

4/3 11
ok k o

2/1
29 1/2   u v

2
3 1/2
2/1

2/1

43 1/4 11 3/4 25 2
3 1/2 3 1/2
1/2 1/2
39 1/4 27 3/4
3 1/2 5 1/2
2 2
3 1/2 43 1/4
2

3 1/2
q r
2/1 7

17 1/2
7

p J l 4

4
NOTE: Pieces N & O are identical

11 3/4 1/2 Akers-Barnes Cockpit - Mark 1

1/2

11
2 1/2
2/1
4/3 51

25 w
3 revision 1.6.1a imperial
M
4/3 91

4/1 3
4/3

2/
NOTE: Pieces J & K are identical Timber 12mm 5ply Plywood or better
2

1
Other Materials 1 x 50cm 2.4cm dameter steel tube (or wood rod)
2

s t
O Copyright Peter Akers & Michael Barnes 1999
v u
2/1 9

s t
n All right reserved
j
9

j n
K
2/1

m i
Ø1 Permission to utilise this design to construct a cockpit, or to adapt

this design to another application, must be obtained in writing or

Ø1
5

5
3 1/2
e-mail from either:  

2
3 1/2

3 1/2
Michael Barnes  Peter Akers. 
1 1/4 17 1/4
michael.barnes@intellection.com.au  akersp@ozemail.com.au 
3 1/2 1 1/4 19 3/4

Figure 2b: The pieces required and their dimensions

The Flying Furniture  ABC Mk 1 Copyright Ó Peter Akers and Michael Barnes, 1999. All Rights Reserved Page 6
 A

L
f d b

aa ab
E B
q r

g p J l
u v aa  
ab

s t

D h m K i
Q
h

v u x
D

A
a b q r
N i l

Should be slightly too wide o k k o

g

on piece (A), to make the

w G x j H k
fight tight.

e c a i l

e f w
C j H k

F
m p s t
c d O m p
B
n nj j n
o
I
n o
I

Figure 3: The relationships between the key dimensions

The Flying Furniture  ABC Mk 1 Copyright Ó Peter Akers and Michael Barnes, 1999. All Rights Reserved Page 7
 v

u
M

L
b a

v
A

aa
x
G w

P i l

x
ab j H k
aa

Q q r
N
ok k o
e f ab  
C

e
m
s

g
F
D h
n
n

c
j

c d

a
aa ab
B
b

aa ab
o

q r
d
h

p J l
p

E
O

s t
n j

K
t

m i

Figure 4: One possible nesting for 2400 x 1200 mm Sheets (Metric Version)

 ABC Mk 1
The Flying Furniture Copyright Ó Peter Akers and Michael Barnes, 1999. All Rights Reserved Page 8
 q
aa

P
b a

m
ab

h
d
b
J

ba

ba
 
L

d
h

D
B
E

aa
aa
o
l

g
c
u v
r

r
i

o k
s

aa

N
s
Q j

f
ab

n
m

j
H

C
a
K

ko
c

e
M
F

O
g

q
i

n j
v u
e

w
t
t

Figure 5: One possible nesting for 1200 x 900 mm Sheets (Metric Version)

 ABC Mk 1
The Flying Furniture Copyright Ó Peter Akers and Michael Barnes, 1999. All Rights Reserved Page 9
Assembly

Assembling the ABC Mk 1 is rather like putting together a jigsaw puzzle.

Start with the seat:

1. Put the side piece (O) in position.

2. Fit the cross pieces (H) and (I) into the slots on the base of (O), putting either (H) or (I) in the forward slot,

depending on your preference of seat position.

3. Put the other side piece (N) in place on the cross pieces.

4. Slide the back support (G) into the upper slots of the side pieces (N) and (O).

5. Slide the seat supporting rod into place through the appropriate holes in the side pieces. Ensure that 5mm or so

protrudes on each side.

6. Place the seat base (M) on top of the front crosspiece and the seat supporting rod, so that the slots in the seat

base are just in front of the rod.

7. Slide the seat back (L) into the slots on the base, and snug it up against the supporting bar. At the top tt should

rest back against the back support (G).

8. Add the side strakes (J) and (K). The tapered ends go to the rear. Tilt them slightly to slip the notches into the

slots on the side pieces, and then lock them down onto the cross pieces. The notches on the outer edges of the

strakes should lock with the tabs on the side pieces.

Add the cushions and your seat is completed!

To assemble the console:

9. Position the left side piece (F)

10. Drop the two cross pieces (B) and (C) into the slots. Piece (B) must go into the slot towards seat section (toward

the sloping front of the side piece).

11. Slide the right side piece (E) into the slots at the other end of the cross pieces.

12. Slot the console top (D) onto the tabs on top of the side pieces. Note that the top is not symmetrical – there is a

‘front’ and a ‘back’. The front will come slightly short of the front edge of the side pieces, to leave room for the

front panel (A). If necessary, flip the console top over.

13. Slot the front panel (A) onto the tabs on the sloping front of the side pieces. A tight fit is best here, to ensure that

you do not accidentally knock the front panel off if you bump it. If necessary, build up the tabs on the side pieces

with some wood filler, or add locking clips to hold the front panel in place. If you construct the front panel with

the slots slightly misaligned, it will make a tight fit that will hold the panel stable.

14. Slot in the required tray piece (P) or (Q) into the front panel through to the cross piece (B). Use the upper or

lower slots as required. Use piece (P) for a keyboard or piece (Q) for a steering wheel.

With the seat and console assembled, simply slide the seat into place in front of the console.

If you are using the steering wheel tray, or do not wish to use the keyboard tray, you can hold your keyboard in place

on the front panel by either:

· Using self-adhesive Velcro strips under the keyboard and on the front panel,

· or screw a rail or support across the bottom edge of the front panel,

· or add pegs or hooks onto the front panel to hang the keyboard on.

Your joysticks can be placed on the side strakes. If you need to fasten them in place, use self-adhesive Velcro

strips, or even Blu-Tack (which, if you don’t know it, is a reusable putty-like adhesive). If you need to run cables

between a joystick and throttle, pass them through the small cut-outs just behind the forward cross-piece.

Adjust the position of the seat, console and your rudder pedals to suit your arm and leg length.  

Happy Flying!

 ABC Mk 1
The Flying Furniture Copyright Ó Peter Akers and Michael Barnes, 1999. All Righ ts Reserved Page 10
APPENDIX  

Trick to print the plans larger, on a A4 (or US letter) printer
Note: These instructions work for most version of Microsoft W ord, though the some of the menu item names

changed between versions.

If you have difficulty reading the plans above, one trick that you can use to print them much larger is to:

· Copy the graphic of the plan. – Right mouse button click on the plan, then select “copy”.

· Create a new blank document. – Click on “File” menu and select “New”.

· Change the margins to the smallest your printer will accept. – Click on “File” menu and select “Page Setup”.

– Set all four margins to 1cm (1/2 inch).

– Click “Ok”

· Paste the plan into the new document. – Click on the “Edit” menu and select “Paste”.

· Enlarge the plan. – Right mouse button click on the plan and select “Format Picture”.

– Click on the “Size” tab and type 160% (110% for the imperial plans) into the

Scale-Height field.

– Click “Ok”

· Zoom out to see the whole page. – Click on the ‘View” menu and select “Zoom”.

– Click on the “Whole page” radio button. Click “Ok”.

· Print this page. – Click on the “File” menu and select “Print”.

· Float the plan. – Right mouse button click on the plan and select “Format Picture”.

– Click on the “Position” tab and tick the “Float over text” check box.

– Click “Ok”

· Print this page. – Click on the “File” menu and select “Print”.

· Now you can discard the document.

You will now have a double sized print out of the plan that can be manually glued together.  

Credits
Thank you to the following people for assistance with the creation of the plans:

· Allen Pawley – for his revolutionary cockpit design, which inspired us to create the ABC Mark 1.

· Peter Creed – for assistance with getting the dimensions correct for metric Revision 1.6

· Frits van Voorst – for prompting the seat cushion discussion.

· Ed Henderson – for the original imperial conversion.

· Andreas (Alien) Elesky – for providing feedback (and corrections) on the imperial plans Revision 1.6.0

· Many others, for corrections and encouragement.  

Version History
Word Doc Metric Imperial

0.1 – 1.3 0.1 – 1.3 - Experimental Versions. None were released to the public.

1.4 1.4 - First Released Version

1.4a – 1.4f 1.4a – 1.4f Various corrections.

- - 1.4d A separate imperial version created and released by Ed Henderson.

1.5 – 1.57 1.5 – 1.57 Experimental Versions. None were released to the public.

First plans to include the Keyboard and Steering Wheel tray.

Other minor corrections.

1.6a –1.6b 1.6.0 1.6.0 Experimental Versions. None were released to the public.

New imperial version included.

Change to the Version Numbering

- a..z designation now indicates changes to this word document.

– the plans will have 0..999 designations and may be different for the metric and imperial

versions. eg. 1.6c of the Word Document contains the 1.60 metric and 1.60 imperial

versions because the text changed but not the plans.

1.6c Version History Added. Printing trick added.

1.6d 1.6.1 1.6.0 Minor corrections. 900x1200 nesting added.

1.6e 1.6.1 1.6.1 Correction to one dimension of part I of the imperial version.

1.6f 1.6.1a 1.6.1a Correction to Michael’s email address

 ABC Mk 1
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