1:3 Scale Mini-Me

To help with the dimensions and packaging, I created a 1:3 scale model of me for the project. First, I found this awesome anthropometric pilot model that the US Air Force used to validate cockpit dimensions in their aircraft designs. Its known as a Two-Dimensional Drawing Board Manikin, and it was actually patented in 1977:

The model is of a male representing the 95th Percentile size of USAF personnel, which equates to 6'2" tall. Since I'm 6'1.5" tall, its about perfect, and it came with several arm and leg variants to fine tune the size. Even better, it already has a helmet on. Incredible...

I measured myself carefully, selected the arm and leg variants that fit me best, and enlarged the manikin image until it was exactly 6'1.5" tall in 1:3 scale (24 1/2 inches.) Then I cut out the pieces, glued them to 1/8" masonite, and cut them out on the jigsaw. I drilled out the mounting holes to articulate the parts accurately. Since I wanted the manikin in 3 dimensions and not two, I made two sets of arms and legs, as well as two sets of hips and ribcage parts. I then assembled them with screws, threaded rod, washers and nuts to create a three dimensional, perfectly articulated pilot model exactly my size. Cool. I haven't decided if I need to add foam "flesh" to the masonite to round out the body and limbs, but its sure a great start for building the interior around the pilot:

I also found the the Cockpit Geometry Design Guidelines published with the manikin in 1982 in the Human Factors tome Anthropometry and Biomechanics: Theory and Application, by Easterby, R.K., K.H.E. Kroemer, and D.B. Chaffin (Eds.) Then, my brother-in-law sent me this way cool link to an audio MP3 of Dennis Wolter (an approx. 57 MB mp3 download), founder of Air Mod, discussing human factors, aesthetics, and safety considerations regarding the interiors of homebuilt aircraft. Its in the Experimental Aircraft Association Historical AirVenture Forums here:

Dennis Wolter of Air Mod Talks About Aircraft Interior Design in July, 2008

These resources will really help me get the driver's seat and controls right, and make the Moonray more comfortable and safer to operate than I would ever have been able to figure out on my own. 

Getting Started on the 1:3 Scale Model

After a long holiday season, I'm back to putting time into the Moonray. The first phase of construction is actually building the vehicle in 1:3 scale. That will allow me to work out the dimensions and design problems relatively easily. There aren't any ready-made parts I can use in this scale, like there would be if I were modeling much smaller in a scale where plastic cars and motorcycle kits were available. Almost everything has to be made from scratch. My 1:3 model will be about 4 feet long, though, so it isn't exactly fine detail work...

I would very much like to find wheels for the model that don't require much work. In my collection of such things I have a wheel I got from American Science and Surplus years ago (I know, don't ask...) that's just about right for the rear wheel. I also had a pair of fronts salvaged from my kids' stroller that were just right for the wheel/tire package I thought I was going to use, but then I scored a uniquely cool pair of front wheels from a Suzuki quad drag racer. They are ultra-rare custom made Douglas 10" x 4" wheels (two inches narrower than stock) with DOT-approved street legal scooter tires already mounted on them. That set is 16 1/2" tall, so I now need to find 5 1/2" wheels to model them accurately on my 1:3 scale Moonray.

I'm currently modeling replicas of the suspension parts and shocks that I have in 1:3 scale. When that's done, I'll work on creating the custom chassis to mount all those parts. Then I'll build the body shell, probably out of cardboard or coroplast, but maybe out of foam. I haven't decided how well to finish the model, but for now just getting the dimensions and packaging right is the goal.