Flight Deck Materials

Flight Decks can be built from a few different materials. Here are some pros, cons, and tips for choosing and working with the materials.

Plywood

Plywood comes in several thicknesses. Probably the most common will be 3/4" and 1/2".

Pros

• Inexpensive
• Easy to find. Most home centers will carry it.
• Easy to work with

Cons

• The grain of plywood is difficult to mask in order to make it look like metal. It will normally take several coats of primer and sanding to create a smooth surface.
• Finding straight pieces can be difficult. Storing it normally forms bows or ripples that may be difficult to remove.
• Swells when wet. Prime all sides.

Builder Tips

• To minimize the amount of end grain showing and/or to save weight, some have tried building a frame of structural lumber and sheathing it with 1/4" plywood such as luan. Getting joints to look good is very difficult using this technique and the thin plywood has more ripples than the thicker versions.
• Using 3/4" ply for a base is less expensive than other materials and the grain can be covered with vinyl or rubber tiles or commercial carpet tiles. It provides something to fasten the MIP and side consoles to, in order to create a more rigid structure.

Medium Density Fiberboard (MDF)

MDF also comes in several thicknesses.

Pros

• Inexpensive. Generally the same price as BC plywood.
• Smooth faces and no end grain. Less sanding needed.
• Stiffer and generally straighter than plywood.
• Works just like plywood. Note that you really need a dust mask when cutting MDF and it will dull saw blades faster than plywood.

Cons

• Heavier than plywood of the same thickness
• Swells when wet. Prime all sides.

Builder Tips

• Make supports and consoles from 3/4" to give them a solid feel. Also provides sufficient glue surface without additional structural bracing.
• To minimize depth when monitors are behind panels like the Main Instrument Panel (MIP), use 1/4" thickness.
• Either 1/4" or 1/2" can be used for other panels, although the 1/2" is more rigid for those long narrow pieces like left and right side panels.
• Use a router and a roundover bit to ease corners. It will look better, and your shins will thank you.

Structural Lumbar

You can use structural lumbar, like 2x4, 2x2, etc. covered with sheet material such as hardboard, polystyrene or polypropylene.

Pros

Cons

Builder Tips

Metal

Using metal, either steel or aluminum, is best for someone wanting a professional/commercial grade of flight deck.

Pros

• Used in real aircraft/spacecraft. Can look very authentic
• Structural strength

Cons

• Expensive
• Need metalworking tools, welders, etc.

Builder Tips

• Steel angle iron can be used to create a structural framework if full enclosure is what you're going for. Its rigid enough that you could mount handholds to the overhead to assist in entry/egress.