Train Simulator Controller: Simulator Takes Shape with Custom Table

For almost three years, I have been building a physical train simulator, modeled on the cab of the UK Class 80x passenger trains like the Class 805, 810, and especially 801 and 802. Creating a train simulator that feels immersive requires more than just virtual reality or detailed software: while having good graphics in a game like Train Sim World or a huge monitor helps, to truly capture the experience of operating (driving) a train, it’s crucial to have a physical dashboard that mimics the layout and feel of a real train’s controls. For my simulator, I’ve created almost every component from the ground up. As detailed in previous blog posts, this has included designing and building a flexible CAN bus transceiver that can interface with any instrument or control, sourcing new or used versions of the real buttons and instruments the trains use, and more recently, performing extensive photographic forensics to determine the shape and size of the prototype’s dashboard panels to recreate them.

I created a cardboard prototype of the center panel of the simulator last year, and at the end of the summer, converted it to a sturdier hardboard version. This first of the five physical panels of the Class 80x dashboard sat on my existing wooden desk for the past few months, very occasionally used for train simulation, but mostly for a combination of software development and as a physical reminder of the project. Notably, it is also only panel that fit on my existing desk in front of my monitor, and even so was extending half off of the desk. My keyboard and mouse barely fit on the amount of desk left, and my heavy CODE keyboard in particular took a few painful headers.

Designing a Custom Table: Why and How

A custom table was necessary to support or partially support the five modules of the Class 80x dashboard, allowing them to surround me in a replica of the real Class 80x cab. While at intermediate points in the project I have considered a simpler simulator merely paying tribute to the Class 80x (and other trains such as the Class 125 Intercity / HST), I eventually refused to settle for anything less than my best effort to precisely replicate a Class 80x.

The first step was figuring out how to properly house the dashboard modules I’ve built. Since I had designed each of the five panels or modules of the dashboard to precisely fit against each other, it was relatively straightforward to project the footprint of each panel down onto a flat surface. There were two additional complications I took into account. First, in the real train cab, the left and center edges of the table extend beyond the front edge of the respective panels, which I incorporated into my design (and which gave me additional space for a keyboard and mouse in the center). Second, several of the panels have instruments that are deep enough behind the panel that when the given panel is canted backwards, the back of the instrument protrudes through the table, so I needed to add cutouts for these instruments. As a final consideration, I live in a small space, and not alone: I needed a dedicated but only semi-permanent table. In other words, I required a surface that would provide the requisite shape, realism, and strength during use but could still be removed and stored when not in use.

My solution is a plywood table that attaches securely but removably to my existing desk with a series of clamps, and is supported at the opposite edge by two adjustable-height IKEA table legs. This way, the table could be easily removed when I want to free up space. But it also needed to be sturdy enough to handle the weight and complexity of the simulator modules.

Constructing the Table

The complex shape of the prototype meant that the table’s edges needed to be precisely cut to follow the complex, angled shape of the train’s real dashboard. Additionally, there are the cutouts to accommodate instruments that protrude from the dashboard below the surface. Therefore, I picked an easily manipulated but strong material for the table: plywood. The table was built in two halves to make cutting and transportation easier, cut from two 2’x4’ sheets of sanded plywood. After laying out the measurements and drafting the requisite CAD drawing, I used a jigsaw to carefully cut the shape of the table. This took time, as the edges of the table needed to follow precise angles and curves to match the Class 80x design. I am at best an amateur woodworker, so I expect that this table is a first draft that I hope to recreate more professionally in the future.

Once the cutting was complete, I had the two halves ready for assembly.

Finishing Touches

The next step was adding the legs and clamps, then attaching the two halves of the table together. The legs were simply screwed into the underside of the two halves at the farthest possible point from the clamps, to minimize the unsupported area of the table surface. This will allow me to adjust the height during use to match the height of my sit-stand desk. I attached the clamps into purpose-cut notches at the edge of the table, then used wood glue and a metal mending plate underneath securely join the two halves together.

Setting Up the Dashboard Modules

Once the table was assembled and securely attached to the desk, it was time to place the dashboard panels on top. I wanted to make sure everything fit perfectly, so I placed each of the five dashboard panels in their designated spots. First I checked that the center panel fit.

I then placed the remaining panels on top, and am evaluating if any of the dimensions will need to be adjusted if I construct a second version of the table.

Current State and What’s Next

With the table and dashboard modules in place, I’m thrilled with how it’s turning out. The semi-permanent design works well for my setup, and I’m able to adjust and store the table with minimal hassle. The most exciting part is how immersive the simulated cab feels.

Next up, I will be wiring up even more of the buttons and controls, and there are still some instruments and buttons I need to source. I also need to finalize my plans for the four LCD panels that fit the large blank areas and open rectangles in the current design. Stay tuned for more updates as I continue to develop the simulator!