CVG DESIGN TEAM
AN INSIDE LOOK AT UNIVERSAL'S CVG DESIGN TEAM
We receive many emails asking how we make our control wheels. We've created this page in an effort to take some mystery out of the process.
In late 2005, Universal assembled a talented design team to recreate airline control wheels with unparalelled accuracy. They studied every aspect of the wheel: dimensions, angles, texture, color, and ergonomics. To achieve this level of realism, the team visits the actual aircraft in which these control wheels are utilized.
Universal holds privileged access to some of the most sophisticated aircraft in the world to include:
Boeing 727, 737, 757, 767 and 777. Regional jet access to CRJ's, ERJ's, ATRs, Saabs, and Dornier's.
Above: Team agent aboard a Boeing 777, with a captain's wheel in the final stages of development.
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Image 1: A small line remains on the right horn of this 777 control wheel where the team broke and re-worked the upper thumb grip. This is common during the Evaluation Phase. For example, during molding of the 757/67 captain's wheel, the left horn was broken and re-worked three times, while the right horn was re-worked more than seven times! The team takes great pride in making the models as accurate as possible-even if it requires an area be re-worked due to a deviation of just an eighth of an inch.
Image 2: Comparison image of the real Boeing 777 control wheel and our cast version-ready for delivery.
Image 3: Studying the wheel and column on board a CRJ. |
Universal's design team devolops control wheels in
a seven-phase process:
| PHASE 1 - Preparation |
| PHASE 2 - Research |
| PHASE 3 - Construction |
| PHASE 4 - Evaluation |
| PHASE 5 - Component Research |
| PHASE 6 - Finalization |
| PHASE 7 - Cast Production |
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Above: Our design team enters the flightdeck of a very new Boeing 737-800NG.
Above: Precision and high fidelity are adjectives that best describe Universal's control wheels. Here the depth of a wheel is being examined using a digital caliper.
Above: Final evaluation of a 757/67 wheel. Note that an error in length and curvature has been found near the trim housing. This would be addressed and corrected prior to molding.
Preparation - Preparing research documents, cameras and measuring devices, ordering of materials, etc.
Research - Visiting the flightdeck of the aircraft being modeled; gathering detailed information, photo's, measurements, etc; ascertaining aircraft manufacturer paint specifications.
Construction - Cutting, sanding, and molding a preliminary model from specially selected wood.
Evaluation - Re-visiting the flightdeck periodically during the construction phase to make fine adjustments.
Component Research - Studying subtle attributes such as pressure to activate, and the minute details of trim switches, activation buttons, knobs, chart holders, and more!
Finalization - Sealing the model with urethane and paint to prepare it for the synthetic molding process.
Cast Production - Design model sent to Universal's Atlanta Wheel Division where a synthetic mold impression is made. Wheels are then cast using a high strength poly-urethane resin and sanded to a polished finish. Following priming, the wheels are shot with an aviation grade PPG paint according to manufacturer color specifications. |