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Visual System - Version 2

It was always planned that the original Visual System would eventually be replaced.
This was finally done in 2009 prior to WorldFlight.

The new visual system resulted in a bigger Simulator footprint.
As a result, the entire Simulator needed to be moved to ensure that adequate clearance was still available.

The simulator was unbolted from the floor, and the surrounding fences and stairs were moved.

A forklift was required to lift the simulator over the chemical bolts and relocate it.

The Simulator in its new position and re-bolted to the floor.

With the design finalised, the new screen was prefabricated in aluminimum and delivered to site.

The screen frame being test fitted to the Simulator.

Support brackets were fabricated and bolted to the Simulator to support the new screen.

The screen frame secured to the Simulator.

Non-slip material was applied to the top of each support bracket and they were painted black.

The area below the brackets was then skinned.

Hatches were constructed to allow access for maintenance.

All inside surfaces were primed and painted matt black.

The material to be used for the new curved screen.

The screen being installed in three pieces.

The completed screen.

Doors were constructed to close the back of the screen off, but still allow access for maintenance.

Work begins on the mounting points for the projectors.

The first projector mounted.

All three projectors mounted.

Testing, aligning and focusing the three projectors.

Work begins on the roof.

Each roof section was a complex shape with complex curves as well.

Final alignment of the projectors. Note the removeable access hatch in the roof.

The completed roof.

The three projectors mounted under the removeable panel.

The left side access door open. The 6 foot ladder gives a good indication of the size of the simulator.

The competed visual system

The first test flight - And yes, it all held together.