Example DIY guide — replace with your own research once you’re ready to publish.

Tools and Materials

Most plywood cockpit shell builds documented by the DIY community use 18mm birch plywood for load-bearing panels and 12mm for non-structural side panels, cut with a track saw or table saw for straight reference edges. A basic tool list: circular saw or table saw, drill/driver, wood screws, wood glue, and a square for checking frame alignment.

Cutting the Base Frame

The base frame is typically built first as a flat rectangle sized to your seat and pedal throw distance, then squared before anything is attached to it — builders consistently flag skipping this squaring step as the most common cause of doors and panels not fitting later.

Assembling the Side Panels

Side panels are generally attached with glue plus screws rather than screws alone, since a glued joint resists the repeated flex from pedal and yoke inputs far better over time. Pre-drilling screw holes near panel edges avoids splitting the plywood.

A Note on Weight and Stability

A full plywood shell adds significant weight versus an aluminum extrusion frame, which is actually an advantage for stability under hard rudder and brake inputs — but it also means planning your build location before final assembly, since these shells are rarely easy to move once complete.