A reproduction Main Instrument Panel (MIP) may appear identical to its OEM counterpart, but there can be there can be subtle differences depending upon which company you purchase a MIP from.
The disparity may not be important to individuals who decide to use a full reproduction flight deck from the same company. However, problems will soon surface if mixing parts from other companies’ or using OEM components.
The following relate to all reproduction MIPS.
The Bezel. The bezel is the frame that surrounds the display units (DUs). In the real aircraft the bezel forms part of the display unit, which is why the bezel breaks open in the lower area; to allow access to and removal of the unit.
If you carefully look you will note there are no screws that hold the bezel in place to the MIP. Quite a few manufacturers use Phillip head screws in each corner of the bezel to attach the bezel to the MIP.
In the real aircraft the bezel is made from machined aluminum.
Landing Gear Lever. The real aircraft has a smaller knob than the one currently used by Flight Deck Solutions. The landing gear knob in the real aircraft is translucent. Further, when the landing gear is in the down and locked position, the red trigger located on the gear shaft completely recesses between the two half-moon protectors and the trigger.
Fuel Flow Reset Switch. The real aircraft uses a switch/toggle with a larger defined and bulbous-looking head, rather than the standard-style toggle most manufacturers use. The OEM toggle is also very specific in operation (3 way pull & release).
The knobs used on the MIP. These knobs are called general purpose knobs (GPK) and it's uncommon for a reproduction knob to look identical to an OEM knob. OEM knobs present with curved rather than straight edges and have the grub screw located in a different position to most reproductions. Many reproduction knobs have the grub screw located at the rear of the knob.
Additionally, OEM knobs have an inside metal shroud (circular metal retainer) and a metal grub screw thread, both important to ensure operational longevity of the knob; reproduction knobs usually do not have this. The metal shroud can be important as it increases the longevity of the knob as it stops the acrylic from being worn down over time with continual use.
The Next Generation also has a backlit, black coloured line that runs adjacent to a translucent line on the front of the knob; at night this line is backlit. Most of the replica knobs have a black line which is a transfer (sticker) that has been hand applied to the knob. Stickers and transfers often lift and peel away, and hand application is often haphazard with some transfers straight and others being off-center.
Annunciators (Korrys). The annunciators on most reproduction MIPs use LED technology and may exhibit an incorrect colour hue in contrast to the OEM part. Reproductions can also be lacking with regard to the legend, as OEM legends are lazer cut and the lettering is very sharp and well-defined.
Annunciators in the real aircraft are illuminated by 28 Volt bulbs contrasting the low brightness LEDs seen in reproduction Korrys - this alone can make a huge difference in aesthetics. Finally, the push to test function seen in the real item, to my knowledge, is lacking in reproductions. Be aware that some newer Next Generation airframes may use LEDs in favour of bulbs.
Colour. Boeing grey (RAL 7011), has a specific RAL colour number; however, rarely is every MIP or aviation part painted exactly the same grey colour; there are sublime differences in shade, colour and hue. Inspect any flight deck and you will observe small colour variations. Type RAL 7011 into Google and note the varying shades for a specific RAL number. OEM and reproduction panels both share varied colour hues of RAL 7011.
Dimensions & 1:1 Ratio. High-end MIPs for the most part are very close to the correct 1:1 ratio of the OEM item and differences, if noticeable, are marginal. But, less expensive MIPs can have the incorrect dimensions. It is not only the overall dimensions that are important, but the dimensions of the spaces, gaps and holes in the MIP that allow fitment of the various instruments and modules.
Whilst this may not be a concern if you are using reproduction gauges that came packaged with your MIP, it can become problematic if you decide to use OEM parts. There is nothing worse that using a Dremel to enlarge a hole in a MIP that isn't quite the correct size. Worse still, is if the hole in larger than it should be.
Musings - Does it Matter ?
If everything fits correctly into whatever shell you're using, then a small difference here and there is inconsequential. However, if you are striving for 1:1, then it is essential to know what is fact and what is fiction (Disneyland).
Important Point:
System Simulation is a Priority
As I move more into the project, I realize that many items available in the reproduction market are not identical to the real aircraft; a certain artistic license has been taken by many manufacturers. This said, while it's commendable to have an exact reproduction of a flight deck, keep in mind that a simulator is primarily a simulation of aircraft systems.
Of course this doesn't mean you throw everything to the wind aesthetically. To do so would mean you would have an office chair, desk and PMDG in front of you. Aesthetics are important, as they stimulate by visual cues a level of immersion, that allows the virtual pilot to believe they are somewhere other than in their own home.
If you inspect real-world flight simulators used by aircraft companies, you will quickly note that many of the simulators do not replicate everything, or strive to have everything looking just like the real aircraft. Simulators are designed for training and whilst a level of immersion must be apparent, replicating aircraft systems takes priority.
Acronyms & Glossary
Annunciator - A single coloured light or group of lights used as a central indicator of status of equipment or systems in an aircraft. Usually, the annunciator panel includes a main warning lamp or audible signal to draw the attention of operating personnel to the annunciator panel for abnormal events or conditions. To annunciate means to display or to become audible. Annunciators are often called Korrys; Korry is a manufacturer of annunciators.
FDS - Flight Deck Solutions
Korry – See Annunciator. A brand of annunciator used in the Boeing 737 airframe.
Legend - The plastic lens plate that clips to the annunciator. the legend is the actual engraved writing on the lense.
MIP - Main Instrument Panel.
OEM - Original Aircraft Manufacture (aka real aircraft part).
RAL - International colour matching system.
