Doc.

No: MCSRDC/JSIM/GR/ CS /01/00

General Requirements
of REPLICA COCKPIT SHELL Date : 08/02/2021
Mission and Combat Page : 1 of 8
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GENERAL REQUIREMENTS
FOR
MANUFACTURING
OF
REPLICA FIGHTER AIRCRAFT COCKPIT SHELL
FOR
FIXED BASE FULL MISSION SIMULATOR (FBFMS)
FOR
JAGUAR AIRCRAFT

Document No : MCSRDC/JSIM/GR/CS/01/00
Date : 08th Feb., 2021

Hindustan Aeronautics Limited

Mission and Combat System Research and Design Centre
Bangalore – 560 017

©Hindustan Aeronautics Limited, MCSRDC, 2021

This document contains proprietary information of Hindustan Aeronautics Limited. This
document is confidential and must not be reproduced, copied, disclosed or utilized in any
way without prior written permission from Hindustan Aeronautics Limited. This should be
used only for intended purpose.

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General Requirements
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Table of Contents
1.0  Vendor Qualification Criteria: ................................................................................. 3 
2.0  Other Requirements .............................................................................................. 3 
2.1.  Design .................................................................................................................... 3 
2.2.  Integration .............................................................................................................. 3 
2.3.  Acceptance ............................................................................................................ 4 
2.3.1.  Factory Acceptance Test (FAT) ............................................................................. 4 
2.3.2.  Site Acceptance Test (SAT) .................................................................................. 4 
3.0  List of deliverables: ................................................................................................ 5 
4.0  Delivery and Program Schedule: ........................................................................... 5 
5.0  Warranty ................................................................................................................ 6 
6.0  Essential Tools....................................................................................................... 7 
7.0  Design Review and Progress Review Meetings .................................................... 7 
8.0  Quality Management System (QMS) Requirements ............................................. 7 
9.0  Endurance .............................................................................................................. 7 
10.0  Total Technical Life ................................................................................................ 7 
11.0  Spares .................................................................................................................... 8 
12.0  Safety, Maintenance and Diagnostic Requirements ............................................. 8 
13.0  Submission of Proposal ......................................................................................... 8 

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General Requirements
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1.0 Vendor Qualification Criteria:

a) Vendor should have manufactured a replica/actual full scale metallic aircraft cockpit
shell. Vendor shall provide the purchase order copies and customer acceptance
certificate as evidence for completion of work.
b) Vendor should have a licensed version of any one of the 3D modeling packages
which support neutral format (IGES/STP) files. Vendor to provide license details or
relevant documents as evidence.
c) Vendor should have at least Two Mechanical engineers on rolls with a minimum of
2 years working experience in design of structures in any one of the 3D modeling
packages. Vendor to provide qualification and work experience details of the
engineers in relevant area as evidence.
d) The requirements at above Para a, b & c are mandatory and offers not meeting
these requirements shall be summarily rejected.

2.0 Other Requirements

2.1. Design

a) Vendor to position Two Mechanical engineers with knowledge of structural design

to MCSRDC, HAL, for initial design of the internal structures of the replica cockpit
shell along with other design related activities mentioned in the technical
requirement document.
b) All necessary hardware and software required for the initial design shall be the
responsibility of the vendor.
c) As other subsystems of the simulator are from other vendors, 10% changes are
expected in design. Vendor to accommodate these changes during fabrication.

2.2. Integration

The following methodology shall be adapted for delivery and integration of each set
of Replica cockpit shell units

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General Requirements
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(a) All the units shall be delivered to HAL, Bangalore as per delivery schedule
mentioned in Para 4.0.
(b) Vendor to carry out integration of other sub systems like integration of Control
column assy., Rudder pedal assy., Throttle assembly, center console assy., LH
and RH panel assy., MIP and beard panel assy., levers & handles assy.,
sensor assy., etc. of the flight simulator at HAL, Bangalore.
(c) Structural support like cutout preparation for electrical connectors, cable/ loom
routings, G-seat and Control loading system integration etc., (other vendor
supplied items) is also responsibility of the vendor.
(d) All necessary materials, equipments and tools required for the above
installation and integration activities are the responsibility of the vendor.

2.3. Acceptance

2.3.1. Factory Acceptance Test (FAT)

a) Factory Acceptance Test (FAT) of Replica cockpit shell will be carried out along
with other subsystems of simulator. Structural fitment checks, Dimensional checks,
mountings, finish etc., will be part of the tests. Vendor is required to participate in
the FAT carried out by the end user and also to take-up necessary modifications to
close all the observations (related to vendors SOW) noticed during the FAT for
acceptance of Replica cockpit shell by HAL/end user.

2.3.2. Site Acceptance Test (SAT)

a) After Successful completion of FAT by end user at HAL, Bangalore, the simulator
will be dismantled and shipped to end user site for installation and commissioning.
The end user sites are located in the northern and western part of India.
b) After successful re-installation of all cockpit shell along with other sub-systems at
end user site, Site Acceptance Test (SAT) procedures will be carried out by the
end user/ HAL for dents, cracks, finish etc. Vendor to take-up necessary
modifications / re-work to close all the observations (related to vendor’s SOW)
noticed during the SAT.

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3.0 List of deliverables:

Following are the list of deliverables in terms of supplies:

Sl.no. Item Description Unit Quantity

Supply of Replica Jaguar cockpit shell with support platform
along with parts and features mentioned in Technical
1 requirements. Doc. No: MCSRDC/JSIM- Nos. 3
DII&DIII/TR/CS/01/00
Supply of Observation platform with features mentioned in
2 Technical requirements. Doc. No: MCSRDC/JSIM- Nos. 3
DII&DIII/TR/CS/01/00
Supply of pilot ladder with features mentioned in Technical
3 requirements. Doc. No: MCSRDC/JSIM- Set 3
DII&DIII/TR/CS/01/00
3D model of the entire Cockpit shell with internal structure
4 in IGES/ STEP format. Set 1

Documentation

5 Hard and two soft (DVD) copies of Mechanical drawings Set 3

(part, assembly and installation drawings) & IPC (Illustrated
parts catalogue).

7 Manufacturer’s recommended spares Set 3

4.0 Delivery and Program Schedule:

The delivery timelines in respect of Replica Jaguar Cockpit shell are given below.
Vendor is required to strictly comply with the time lines.

REPLICA JAGUAR COCKPIT SHELL Activities Time line

Placement of P.O T0
Design by vendor at HAL, Bangalore T0+01Month
Preliminary Design Review (PDR) T0+02 Months
Critical Design Review (CDR) T0+06 Months
First set of cockpit shell with ladders
Predespatch inspection of 1st set at vendor’s place T0 + 11 Months
Delivery of 1st Set T0 + 12 Months
Integration of items supplied by other vendors for 1st set T0 + 16 Months
Factory Acceptance Test of 1st set at HAL, Bangalore
T0 + 20 Months
with end user
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General Requirements
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Site Acceptance Test at 1st customer site along with end

T0 + 22 Months
user
Second set of cockpit shell with ladders
Predespatch inspection of 2nd set at vendor’s place T0 + 16 Months
Delivery of 2nd Set T0 + 17 Months
Integration of items supplied by other vendors for 2nd set T0 + 21 Months
Factory Acceptance Test of 2nd set at HAL, Bangalore
T0 + 23 Months
with end user
Site Acceptance Test at 2nd customer site along with end
T0 + 25 Months
user
Third set of cockpit shell with ladders
Predespatch inspection of 3rd set at vendor’s place T0 + 26 Months
Delivery of 3rd Set T0 + 27 Months
Integration of items supplied by other vendors for 3rd set T0 + 30 Months
Factory Acceptance Test of 3rd set at HAL, Bangalore
T0 + 32 Months
with enduser
Site Acceptance Testing at enduser site along with end
T0 + 34 Months
user

Note: The items should be supplied as per the delivery schedule indicated above.
As time is the essence of this program for integration of other subsystems of the
simulator, significant deviations from the schedules will not be acceptable to HAL
and may render the bid submitted by the vendor liable to be rejected.

5.0 Warranty

a) The items supplied by the vendor shall carry onsite warranty for 24 months from
the date of acceptance by HAL. The items supplied and materials used shall be
free from all types of defects/ failures.
b) If within the period of warranty, the goods/ services are reported by the HAL/end
user to have failed to perform as per the specifications, the vendor shall replace the
item within 2 days and rectify the defective items free of charge, maximum within
30 days of notification of such defect by the HAL/end user provided that the goods
are used and maintained by the HAL/end user as per instructions contained in the
Operating Manual. Warranty of the equipment would be extended by such duration
of downtime. Record of the down time would be maintained by user in log book.
c) The vendor also undertakes to repair/ replace the goods/ equipment arising due to
accidents by neglect or misuse by the operator or damage due to transportation of
the goods during the warranty period, at the cost mutually agreed to between the
HAL/end user and the vendor. The vendor shall intimate the assignable cause of
the failures.

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d) If any item/s fail frequently and/ or, the cumulative down time exceeds 5% of the
warranty period or a common defect is noticed in more than 10% of the quantity of
goods with respect to a particular item/ component/ subcomponent, that complete
item/ equipment shall be replaced free of cost by the vendor within a stipulated
period of 45 days of receipt of the notification from HAL/end user duly modified/
upgraded through design improvement in all equipment supplied/ yet to be supplied
and spares supplied and yet to be supplied.

6.0 Essential Tools

The tools those are in repetitive use and also for regular maintenance and operation
of the Cockpit shell are required to be supplied to HAL along with the Replica jaguar
cockpit shell. Vendor’s technical proposal shall consist of the list of such tools and
test equipment.

7.0 Design Review and Progress Review Meetings

a) Vendor should participate in the Design Review and Progress Review meetings
that would be planned for design and development of Replica Jaguar Cockpit shell.
Vendor to incorporate the changes proposed during PDR and CDR in the cockpit
shell design before initiating fabrication.
b) Weekly review meeting are compulsory and therefore a vendor representative with
complete authority and responsibility shall be nominated for participating in the
review meetings.

8.0 Quality Management System (QMS) Requirements

Vendor shall have Quality Management System (ISO 9001) or Aerospace AS9100
certification / approval and required to submit the copy of the same along with the
technical offer.

9.0 Endurance

The items supplied by the vendor should meet the requirement for daily operations of
Ten (10) hours with continuous operations of minimum eight (08) hours.

10.0 Total Technical Life

All the equipment/ systems supplied by the vendor should have a total technical life
of 20 years.

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11.0 Spares
Vendor is required to provide the list of spares that are part of delivery. Also, vendor
is required to provide the Manufacturer’s Recommended List of Spares (MRLS)
along with unit cost. Vendor is required to indicate the criticality (low, medium and
high) of spares recommended based on the past experience.

12.0 Safety, Maintenance and Diagnostic Requirements

1. The Replica cockpit shell shall use a LRU (Line Replaceable Unit) concept to ease
field maintenance, replacement and spares support.
2. Replacement of the LRU’s should be easily achieved by the maintenance crew.
3. The system shall have provision to monitor and repair/replace the sensors and
actuators.

13.0 Submission of Proposal

Para wise compliance table with respect to technical requirements of Replica Jaguar
cockpit shell document along with relevant technical details to support the
compliances. Response to each requirement shall contain adequate details for the
means of compliance instead of merely stating “Complied”.

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 TECHNICAL REQUIREMENTS

FOR

MANUFACTURING

OF

REPLICA FIGHTER AIRCRAFT COCKPIT SHELL

FOR

FIXED BASE FULL MISSION SIMULATOR

FOR

JAGUAR AIRCRAFT

Document No : MCSRDC/JSIM-DII&DIII/TR/CS/01/00
Date : 08th Feb., 2021

Hindustan Aeronautics Limited

Mission and Combat System Research and Design Centre
Bangalore – 560 017

©Hindustan Aeronautics Limited, MCSRDC, 2021

This document contains proprietary information of Hindustan Aeronautics Limited.
This document is confidential and must not be reproduced, copied, disclosed or
utilized in any way without prior written permission from Hindustan Aeronautics
Limited. This shall be used only for intended purpose.
 Technical Requirements Doc.No: MCSRDC/JSIM-DII&DIII/TR/CS/01/00
for REPLICA COCKPIT Date : 08/02/2021
Mission and Combat SHELL Page 3 of 23
System R&D Centre

Table of Contents

1.  Introduction ................................................................................................... 5 

2.  Purpose.......................................................................................................... 5 
3.  Brief of Replica Cockpit shell with Ladders .............................................. 5 
3.1.  List of activities for manufacture of replica cockpit shell ........................ 6 
3.2.  Cockpit Shell Structure ................................................................................ 7 
3.3.  Canopy & Wind Screen ................................................................................ 8 
3.4.  Dummy Inflight Refuelling Probe .............................................................. 10 
3.5.  Glare Shield ................................................................................................. 10 
3.6.  Replica HUD ................................................................................................ 11 
3.7.  Dummy H32α Box ...................................................................................... 12 
3.8.  Map box ....................................................................................................... 12 
4.  Main Panel Instrument ............................................................................... 13 
5.  Centre console support structure ............................................................ 14 
6.  Left Hand (LH) CONSOLE .......................................................................... 15 
7.  Right Hand (RH) CONSOLE ....................................................................... 16 
8.  COCKPIT FLOORING ................................................................................. 18 
9.  Cockpit Support Platform .......................................................................... 19 
9.1.  Top and Bottom support Frames .............................................................. 19 
9.2.  Vertical support Frames ............................................................................ 19 
9.3.  Wheels and Screw Jacks ........................................................................... 19 
9.4.  Mounting plates with Acrylic covers ........................................................ 20 
10.  Observation Ladder .................................................................................... 20 
10.1.  Bottom frames ............................................................................................ 20 
10.2.  Steel Hand Rail with supports ................................................................... 20 
10.3.  Steps ............................................................................................................ 21 
11.  Pilot Ladder ................................................................................................. 21 
12.  Workmanship .............................................................................................. 22 

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12.1.  Design and Construction ........................................................................... 22 

12.2.  Name Plates and Product Markings ......................................................... 22 
12.3.  Operational Environment........................................................................... 22 
12.4.  Human Engineering .................................................................................... 22 
12.5.  Packing and Transportation ...................................................................... 23 

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1. Introduction
MCSRDC, HAL is carrying out Design and Development of Fixed Base Full
Mission Simulators (FBFMS) of fighter aircraft for supply to its customer. One of the
deliverable items of FBFMS is a Full scale Replica cockpit shell along with support
platform and ladders. The objective of the fully integrated replica cockpit shell is to
give the trainee pilot the actual feel of flying the fighter aircraft. The cockpit shell
shall be an exact replica in terms of form and fit as per the fighter aircraft cockpit
model.
The fabrication and supply of replica cockpit shell shall be for quantity 3 nos.
Cockpit shell of DARIN II variant shall be 1 no. and cockpit shell of DARIN III variant
shall be 2 nos. The size and shape of the replica cockpit shell of DARIN II & DARIN
III remains same except the Main instrument panels, LH and RH panels. The same
is brought out in the respective Para’s.

2. Purpose
The purpose of this document is to define the technical requirements for
design, manufacture, integrate, and delivery of the cockpit shell along with the
support platform, observation and pilot ladder to HAL for further equipping, testing
and acceptance. The scope of Work (SOW) and other requirements is brought out at
subsequent sections of this document.

3. Brief of Replica Cockpit shell with Ladders

The layout of cockpit shell with ladders is shown in Fig.1. The cockpit shell shall
be a metallic structure representing in shape and size of a fighter aircraft cockpit
model.

COCKPIT SHELL

OBSERVATION
LADDER

SUPPORT
PLATFORM

PILOT
LADDER

Fig. 1 – Layout of Cockpit Shell with Ladders

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The shell shall be approximately 3500 mm (L) x 1000 mm (W) x 1700 mm (H).
The cockpit shell shall be positioned rigidly on a support platform of approximately
3000 mm (L) x 1100 mm (W) x 1250 mm (H). A pilot ladder 2500 mm (H) x 300 mm
(W) and an observation ladder 1900 mm (L) x 800 mm (W) x 1800 mm (H) shall be
fabricated and positioned on either side of the cockpit shell. Both the support
platform and the observation ladder shall be movable with wheels and screw jacks.
Items supplied by other vendors like flight controls (control column, rudder pedal &
throttle), G-Seat, Control loading system(CLS), assembled LH and RH panels etc.,
are to be installed inside the cockpit at HAL, Bangalore.

3.1. List of activities for manufacture of replica cockpit shell

The following list of activities is to be carried out by the vendor for the manufacture
of replica jaguar cockpit shell.

a) Fabrication of cockpit shell

(i) Design, Fabrication and assembly of frames, longerons, stiffeners, seat
mounting bracket, cockpit floor, inner and outer cockpit skin etc.,
(ii) Design, Fabrication and Assembly of removable type shelves along with
its supports in forward and aft of the shell.
(iii) Fabrication and Assembly of Main Instrument panels (MIP) and beard
panel along with its supporting structures.
(iv) Fabrication and Assembly of glare shield with its supports.
(v) Fabrication and Assembly of LH and RH consoles with its supports and
attachment structures.
(vi) Design, Fabrication and Assembly of Replica HUD with its support
structure.
(vii) Design, Fabrication and Assembly of canopy and its frame & wind
screen, with its supporting structures.
(viii) Design, Fabrication and Assembly of dummy inflight refuelling probe
with its supports and attachment brackets.
(ix) Design, Fabrication and Assembly of Mounting brackets to suit sensors
for Control column pedestal, Throttle & Rudder pedals. (Sensors will be
supplied by MCSRDC, HAL.)
b) Integration of Throttle box, Control column pedestal and Rudder pedal
assembly. (Items will be supplied by MCSRDC)
c) Integration of LH & RH Main Instrument Panels, LH & RH Console panels
(Items will be supplied by MCSRDC).

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d) Fabrication of movable cockpit support platform.

e) Fabrication of observation and pilot ladder.
f) Painting of cockpit shell with logos as per scheme given by MCSRDC.
g) Support required for integration of the items supplied by other vendors.

3.2. Cockpit Shell Structure

The Figure 2 shows the cockpit shell structure and the fabricational details of
the shell are given below.

Fig 2 – Cockpit Shell Structure

a) The cockpit shell shall be a 1:1 metallic structure and shall have external skin
made of 6061, T6 aluminium alloy sheet of 2 mm thickness. The external &
internal shape and size of the shell shall be as per HAL supplied 3D model.
The skin shall be anodized as per standard procedure before assembly.
b) The frames and stiffeners shall be made of 2mm thick 6061, T6 Aluminium
alloy sheet and extrusions. The number of frames and its positioning shall be
as per the HAL supplied 3D model (Details of dimensions between the frames
will be provided during design phase). The frames shall be interfaced between
the outer and inner skins of the cockpit shell. The outer flange of the frames
shall suit to the contour of the external cockpit shell skin and the inner flange of
the frame shall suit to the internal cockpit shell skin of the shell.
c) The cockpit external skin structure shall have provision for access cut-outs
along with closing panels and with quick release fasteners. The location of the
cut outs shall be decided during the development stage.
d) All the access cut-outs shall be covered with removable panels. These panels
shall be flush fitted and firmly secured and shall look like original aircraft
panels. Access panels to have quick release fasteners for easy removal and
fitment.

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e) The internal and external finish (including markings and logo) of the shell shall
be decided after cockpit build up. Details will be provided after placement of
PO.
f) The cockpit shell shall have removable type hard points for lifting and
positioning the entire cockpit shell in fully equipped condition on the support
platform. The location of these hard points shall be decided during the design
phase by both HAL and vendor.
g) The cockpit shell shall be designed with provision of locking the shell rigidly to
the bottom support platform. The locking of the shell should be easily
accessible in equipped condition of the cockpit shell on the support platform.
h) The cockpit shell equipment panels (like MIP, LH & RH console panels) shall
have provision for integrating all the items supplied by MCSRDC (like LRUs,
switches, indicators etc.,) with provision for easy maintenance and removal.
i) The external & internal details and shape & size shall be provided in the 3D
model of the cockpit shell in “IGES or STP” format.
j) The Front and Rear openings of the cockpit shell shall be suitably closed with
rigid covers made of 6061, T6 Aluminium Alloy sheet of suitable thickness. The
covers shall be removable type with self-locking latches and they shall be in
flush with the external surface of the cockpit shell.
k) Design and fabrication of mounting structures for installation of sensors for
flight controls shall be provided. Details of the sensors mounting brackets with
its location shall be decided during development stage.
l) Racks for installation of LRUs, computer peripherals and its accessories in
forward and aft of the cockpit shell shall be fabricated using aluminium alloy
sheet of 2.5mm thick with appropriate stiffening.

3.3. Canopy & Wind Screen

The Figure 3 shows the canopy and windscreen. The fabrication details of the
canopy and windscreen are given below.

a) Canopy and wind screen shall be fabricated as per HAL supplied 3D model.
b) The Canopy bubble shall be fabricated using Polycarbonate/acrylic sheet of
5mm thickness and canopy frame shall be fabricated using aluminium alloy
material. Canopy bubble shall be mounted firmly to the canopy frame, using
CSK commercial screws. The assembly after installation on cockpit shell shall
replicate Jaguar a/c canopy in all aspects including canopy opening and
closing (Rear side). The canopy shall be equipped with mirror at forward of
canopy.

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c
Canopy

Wind
screen b

a = 1180mm; b = 1050mm ; c = 814mm

Fig. 3. – Canopy & Windscreen

c) Vendor to carry out the canopy locking mechanism design, both external and
internal along with closing and opening levers and handles. It shall have
provision to operate canopy locking and unlocking from both inside and
outside of the cockpit. The same shall give the feel of actual aircraft locking
mechanism.
d) Vendor to propose to HAL, the canopy operating lever/handle design.
e) Canopy bubble shall be free from air bubbles and vision distortion and shall
have uniform contour as per Jaguar canopy.
f) The windscreen frame is to be fabricated in three pieces using commercial
Aluminium alloy material. Windscreen shall be fabricated using
Polycarbonate/acrylic sheet of 5mm thickness and it shall be mounted firmly to
the windscreen frame using suitable CSK screws.
g) Windscreen frame shall have mounting provision and shall have contour
suiting as per HAL supplied 3D model. Windscreen with frame shall replicate
actual aircraft shape and size in all aspects
h) Windscreen frame shall have provision for mounting brackets for installation of
accelerometer, G-meter and clock.
i) The aft of the windscreen shall be provided with rubber seal (contact surface
with canopy).
j) Wind screen shall be free from air bubbles and free from vision distortion and
shall have uniform contour as per Jaguar wind screen

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3.4. Dummy Inflight Refuelling Probe

a

Nozzle

Probe
b

a = 800mm; b= 500mm
Fig. 4. – Dummy Inflight Refuelling Probe

The Dummy Inflight refuelling probe is shown in Fig-4. The entire refuelling
probe assembly with Nozzle is to be fabricated using acrylic material. The shape,
size and finish of the refuelling probe along with nozzle shall be as per supplied 3D
model and shall represent the actual aircraft probe. The Probe assembly shall be
flange mounted to the cockpit shell using nut-plate & bolts (removable when not
required). Necessary hard points inside the cockpit shell to support the probe shall
be provided. The external finish including markings of the probe assembly will be as
per the existing aircraft finish (details will be provided after placement of PO).

3.5. Glare Shield

b

a = 965mm; b= 690mm; c = 570mm

Fig. 5. - Glare Shield

The Replica Glare shield is as shown in Fig-5. The glare shield is to be

fabricated using FRP material of 2 mm thickness with suitable reinforcement. The
shape and size of the glare shield shall be as per HAL supplied 3D model.
a) Glare shield with forward and aft mounting provision shall be provided to
mount on side longeron supports of cockpit shell.

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b) L-Angle brackets for mounting switches and indicators shall be part of Glare
shield assembly. All switches and indicators will be supplied by MCSRDC. The
size, shape and other details of the brackets shall be finalized during
development.
c) Glare shield shall have provision for mounting Auto Pilot Control Panel
(APCP), Channel selector, Anti-Flash lights, Flood lights, Break connector
brackets and cleats for supporting the looms.
d) Glare shield shall be finished with Matt black paint with one coat of primer.

3.6. Replica HUD

UFCP

b HUD
c

HUD Mounting
a = 725mm; b= 125mm; c = 170mm;

Fig 6 – Replica HUD

The replica HUD shall be designed and fabricated as shown in fig.6. The size
and shape of the replica HUD shall be same as the existing aircraft HUD (3D model
of existing aircraft HUD shall be provided). 6061, T6 aluminium alloy sheet shall be
used for fabricating the replica HUD. The HUD shall be mounted rigidly on the MIP.
The replica HUD with its mounting provision shall be easily assembled &
disassembled from MIP from the front using bolts and in the rear using dowel pins.
The Replica HUD shall have provision for mounting the Up Front Control Panel
(UFCP) as shown in fig.6. The Up Front Control Panel (UFCP) functional unit will be
supplied by MCSRDC during development. HUD casing shall have provision for
mounting cleats for routing the looms of UPCP.

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3.7. Dummy H32α Box

a

a = 300mm; b= 190mm

Fig. 7. – Dummy H32α Box

A Dummy H32α box shall be fabricated as per HAL supplied 3D model. 6061,
T6 aluminium sheet shall be used for fabrication. The dummy H32α box shall be
fitted on the RH panel as per the supplied 3D assembly model and in the same
location and orientation. Commercial fasteners (nut-plates and bolts) are to be used
for the assembly and installation of the box in the cockpit. Dummy H32α Box is to be
finished with Matt black paint with one coat of primer along with the same text.

3.8. Map box

a = 200mm; b= 190mm

Fig. 8 – Map Box

The Map box is to be fabricated and integrated as per HAL supplied 3D model.
6061, T6 Aluminium sheet of 1.5mm thickness shall be used for the fabrication.
Commercial fasteners are to be used for the assembly and installation of the box on

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side of console. The Map box shall be finished with Matt black paint with one coat of
primer.

4. Main Panel Instrument

CENTRE
CENTRE CONSOLE
CONSOLE LH MIP
LH MIP RH MIP RH MIP

a
a

b b
a = 450mm; b= 670mm

Fig 9 - DARIN II VARIANT MIP Fig 10 - DARIN III VARIANT MIP

Main Instrument Panels (MIP) with cut-outs for installation of instruments,

switches, indicators and displays etc., (All instruments, switches, indicators and
displays etc., will be supplied by HAL during assembly at HAL) shall be fabricated as
per the HAL supplied 3D models. The supply of these panels shall be 2 nos. for
Darin III and 1 no. for Darin II variant cockpit shells.
a) The MIP panels and its assemblies shall be fabricated in separate pieces (LH &
RH). The MIP panels along with beard panels shall be mounted on the centre
console assembly.
b) The MIP panels shall be made up of Machined 6061, T6 Aluminium Alloy
material and the beard panels shall be made of 2mm thick aluminium panels
which in turn shall be mounted on Dzues rails.
c) For easy maintenance, The MIP mountings shall be designed for easy assembly
& disassembly from cockpit receiving structure using nut-plates and bolts.
d) MIP panels shall be painted with black colour (matt finish) with one coat of
primer.

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5. Centre console support structure

d

c
a

a = 700mm; b= 470mm; c= 400mm ; d=190mm

Fig. 11 – Center Console Support structure

The replica centre console support structure is as shown in fig.11. The centre
console structure is used to support the Main Instrument Panel, beard panel and
dummy HUD. The centre console shall be fabricated in two separate supports (LH
& RH) and joined in between using support plate as per the supplied 3D model and
shall be fabricated using 6061, T6 Aluminium alloy block material. The support
structure shall have four mounting points for mounting on the floor of cockpit and
another two mounting point at cockpit forward bulkhead.
Vendor to design and fabricate a suitable support brackets for mounting MIP,
HUD mounting Tray, beard panel, replica displays and Rudder pedal adjuster box
assembly.
Cleats/ Jumpers shall be provided on the sides of the support structure to
route looms on the structure. Centre Console support structure is to be painted with
black colour (matt finish) with one coat of primer.

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6. Left Hand (LH) CONSOLE

Side cover

Fig. 12 – LH Console
Top Panels

Support
Structure

Fig. 13 – LH Console Support Structure

a) Fig 12 shows the LH console with all items in installed condition. All LRUs,
switches and indicators will be supplied by HAL. Vendor to fabricate the
blank panels with cut outs. The cut out details with dimensions will be
provided by HAL during development stage.
b) Left Hand console of approximately 915mm (L) and 190mm (W) (Refer
Fig.12) structure shall be fabricated using 6061, T6 Aluminium Alloy and
supported on Dzues fastener rails. These rails shall be interfaced with the
structure as per HAL supplied 3D model.
c) LH console shall consist of support structure, side covers and top panels for
installing switches, panels and controls (All switches, CBs and LRUs will be
supplied by HAL).
d) Fig. 13 shows the Support structure for mounting all the top panels. The
support structure shall be fabricated from 6061, T6 Aluminium alloy extrusion

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angles and sheets. The size, shape, location and orientation shall be as per
HAL supplied 3D model. The support structure for the console shall be
provided with mounting points for installation of throttle box, control panels,
switch panels, blanking panels and side covers with suitable fasteners/
Dzues fasteners. Wire lock rails at the edges shall be riveted to the support
structure as per the HAL supplied 3D model.
e) Side covers in three pieces shall be fabricated from 6061, T6 aluminium
sheets of 2mm thickness. The side covers shall be easy removable for wiring
and servicing of items.
f) Top panels along shall be fabricated from 6061, T6 aluminium sheet of 2 mm
thickness. The shape, size and no. of panels shall be as per HAL supplied
3D model. All top panels shall be mounted with Dzues fasteners suiting the
wire lock rails. Panels with cut outs and Dzues fasteners shall be fabricated
and supplied along with the shell.
g) Fitment of Throttle box and other items in LH Console shall be in the same
location and installation as per supplied 3D model and these items shall be
supplied by MCSRDC during development stage.
h) Provision for routing electrical looms shall be provided inside the LH
Console. Support bracket, cleats/jumpers and cut-outs shall be provided for
loom securing and routing.
i) LH console top panels shall be painted with black paint and support structure
and side covers with cockpit grey paint (matt finish) along with one coat of
primer.

7. Right Hand (RH) CONSOLE

Top Panels

Side panel
Figure 14 – RH Console

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Support structure

Figure 15 – RH Console Support Structure

a) Fig 15 shows the RH console with all items in installed condition. All LRUs,
switches and indicators will be supplied by HAL. Vendor to fabricate the blank
panels with cut outs. The cut out details with dimensions will be provided by
HAL during development stage.
b) Right Hand console of approximately 940mm (L) and 200mm (W) (Refer Fig.
14) shall be fabricated using 6061, T6 Aluminium Alloy and supported on
Dzues fastener rails. These rails shall be interfaced with the structure as per
as per HAL supplied 3D model.
c) RH console shall consist of support structure, side covers and top panels for
installing switches, panels and controls (All switches, CBs and LRUs will be
supplied by HAL).
d) Fig. 15 shows the Support structure for mounting all the top panels. The
support structure shall be fabricated from 6061, T6 Aluminium alloy extrusion
angles and sheets. The size, shape, location and orientation shall be as per as
per HAL supplied 3D model. The support structure for the console shall be
provided with mounting points for installation of control panels, switch panels,
blanking panels and side covers with suitable fasteners/ Dzues fasteners.
Wire lock rails at the edges shall be riveted to the support structure as per the
HAL supplied 3D model.
e) Side covers in three pieces shall be fabricated from 6061, T6 aluminium
sheets of 2mm thickness. The side covers shall be easy removable for wiring
and servicing of items.
f) Top panels along shall be fabricated from 6061, T6 aluminium sheet of 2 mm
thickness. The shape, size and no. of panels shall be as per HAL supplied 3D
model. All panels shall be mounted with Dzues fasteners suiting the wire lock
rails. Panels with cut outs and Dzues fasteners shall be fabricated and
supplied along with the shell.

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g) Provision for routing electrical looms shall be provided inside the RH Console.
Support bracket, cleats/jumpers and cut-outs shall be provided for loom
securing and routing.
h) RH console top panels shall be painted with black paint and support structure
and side covers with cockpit grey paint (matt finish) along with one coat of
primer.

8. COCKPIT FLOORING

Seat Support
Attachment

Cockpit Floor
Fig. 16 - Cockpit Flooring

a) Cockpit flooring shall be made with 6061, T6 Aluminium alloy sheet of 3mm
thickness. Cockpit flooring shall have sufficient reinforcement for installation of
G-seat, flight controls and centre console assembly. The shape and size of the
cockpit floor shall be as per HAL supplied 3D model.
b) Floor shall be rigid enough to sustain loads of approximately 500 Kg of Weight
(G-Seat assy.: 100 Kg, Pilot Weight: 100 Kg, LH &RH console assy.: 100 Kg,
Centre Console assy.: 200 Kg).
c) Separate trenches & cut outs for routing of power and data cables shall be
provided underneath the LH & RH consoles area of the cockpit floor.
d) Hinges/clamps/brackets/Bell crank levers shall be provided on the flooring for
the fitment of Rudder pedal assembly, Control Column in their respective
locations as per HAL supplied 3D model. The seat support shall be fabricated
using EN 8 Mild steel and other hinges and brackets shall be fabricated using
Aluminium alloy 6061, T6.
e) The cockpit floor shall be anodised and painted in cockpit grey colour with one
coat of primer.

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9. Cockpit Support Platform

Top support Frame

Mounting plates with

acrylic covering

Vertical support Frames

Bottom support Frames

Fig. - 17 Cockpit support platform

The Cockpit support platform of 3000 mm (L) x 1100 mm (W) x 1250 mm (H)
(Fig.17) shall be fabricated as per HAL supplied 3D model. The cockpit support
platform shall be used to position the cockpit shell rigidly and also for mounting
other electrical and electronic accessories. The support platform shall be made in
three parts viz., top support frames, bottom support frames and vertical support
frames along with flanges, wheels and screw jacks. The details for development of
support platform are given below.

9.1. Top and Bottom support Frames

Mild steel, EN 8 material of 60mm square cross section with 2.5mm wall
thickness shall be used to fabricate the gussets, top and bottom frames of the
platform. The frames shall be joined by welding. Square flanges of 5mm thickness
shall be welded to the ends of the frames. All frames shall be painted with one coat
of primer and finished with two coats of matt black paint.

9.2. Vertical support Frames

Mild steel, EN 8 material of 100mm square cross sections of 2.5 mm wall
thickness shall be used to fabricate the vertical support frames of the platform. The
frames shall be joined by welding. All open ends of the frames shall be welded with
mounting flanges of 5mm thickness. All frames shall be painted with one coat of
primer and finished with two coats of matt black paint.

9.3. Wheels and Screw Jacks

Rotatable Teflon wheels (with brakes) with 150mm wheel base diameter
along with screw jacks shall be fitted as shown in fig. 17.

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9.4. Mounting plates with Acrylic covers

6061, T6, Aluminium alloy sheets of 4mm thickness shall be used to fabricate
the mounting plates (2 nos.). These plates shall be used for mounting the electrical
and electronic equipment’s. The plates shall be mounted in between the top and
bottom support frames as shown in Fig.17 and shall be painted with one coat of
primer and finished with two coats of matt black paint.
Acrylic sheet of 3 mm thickness shall be used to fabricate the covers for the
mounting plates. These acrylic sheets shall be assembled to the support plates with
suitable spacer blocks near the mounting area.

10. Observation Ladder

The observation ladder of approximately 1900 mm (L) x 800 mm (W) x 1800m
(H) shall be fabricated and delivered as per the requirement below.

Acrylic sheet
Steel Hand Rail

Hand Rail support

Bottom Frame

Figure 18 – Observation Ladder

10.1. Bottom frames
Bottom frames and cross beams of the ladder shall be fabricated using MS
frames of 40mm square cross section of 2mm thickness. Self-locking rotatable
Teflon wheels with screw jacks shall be welded to the bottom frames as per fig.18.
The bottom frames shall be painted with one coat of primer and finished with two
coats of matt black paint.

10.2. Steel Hand Rail with supports

40mm diameter SS 304 stainless steel tubes of 1 mm wall thickness shall be
used for fabrication of hand rail and support. The stainless steel hand rails along
with the supports shall be bolted rigidly to the MS bottom frames using suitable
steel bolts and nuts.
The open spaces in between the steel hand rails shall be covered with clear
Acrylic sheets of 10mm thickness using steel plates.

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10.3. Steps
The ladder steps shall be fabricated using MS frames of 40mm square cross
section. Plywood board of 20mm thickness shall be bolted to the MS frames. The
bolt heads shall be counter sunked into the wooden Ply board. The wooden steps
shall be covered using felt cloth of 2mm thickness (red colour) using suitable
adhesive. The MS frames of the steps shall be painted with one coat of primer and
finished with two coats of matt black paint.

11. Pilot Ladder a

a = 300mm; b= 2600mm

Figure 19 – PILOT LADDER

The pilot ladder of approximately 2600 mm (H) x 300 mm (W) shall be used
for the pilot to get into the cockpit shell. The Frames and cross bars of the pilot
ladder shall be fabricated using 6061, T6 Aluminium tubes of 30mm cross section &
2mm wall thickness. The cross bars and the frames shall be welded. The top
platform shall be made of corrugated aluminium sheet of 3mm thickness. Sufficient
stiffeners shall be provided for the top platform to withstand the weight of the pilot.
The ladder shall be flange mounted to the cockpit shell using bolts. Sufficient hard
points shall be provided inside the cockpit shell structure for mounting the ladder.
Pilot ladder shall be painted with one coat of primer and finished with two coats of
matt black paint.

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12. Workmanship

12.1. Design and Construction

All design activities shall be carried out at MCSRDC, HAL premises. Basic
design data like cockpit external and internal NMG, LH & RH MIP’s and panels etc
shall be provided in 3D IGES/STP format. The internal structural design between
the external and internal skin along with the mounting structures shall be designed
by the vendor in coordination with MCSRDC, HAL structural design team.
Design data of other supplier’s items which are required to be installed in the
cockpit shall be shared to the vendor as and when the data is received from them.
Details of all the structural components, parts and assembly along with C-class
items details shall be clearly mentioned in the Bill of Materials (BOM) of the
Structural design drawings.
Standard industry practices shall be followed during all stages of fabrication,
welding, painting, assembly etc.
External surface shall have good aesthetic and smooth contours and shall
have no gaps in between two mating skins. No sharp edges are allowed.

Note: Design concurrence from MCSRDC, HAL to be taken for all design
related tasks before initiating fabrication.

12.2. Name Plates and Product Markings

Size of marking characters shall be appropriate to the size of the part and shall
be located on non-functional surfaces.
Marking shall be applied directly to the part surface using a method, which will not
degrade the surface (using paint or sticker).

12.3. Operational Environment

The Replica Cockpit shell is designed to operate in room with temperature of

18 to 50 degree Celsius. Panel design shall provide for adequate positioning and
spacing of components to permit sufficient dissipation of heat and excessive
temperature in their immediate environment. The air temperature inside the shell
shall not rise above the safe operating temperature of any of the components
contained inside the shell.

12.4. Human Engineering

The cockpit sub-system shall provide the following working environment

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a) Areas below cockpit floor shall contain adequate space for tasks that are
required to perform during operation and maintenance under normal
conditions.
b) Labels, legends, placards, signs, markings, or a combination of these shall be
provided whenever it is necessary for personnel to identify, interpret, follow
procedures, or avoid hazards.

12.5. Packing and Transportation

Deliverable items shall be prepared for shipment and shipped in accordance

with the purchase order. Shipments are under the responsibility of vendors.
The cockpit shell needs to be shipped to HAL on road. Shipments of the cockpit
shells shall have adequate control of the packaging to ensure that the quality of the
delivered item(s) is maintained and that damage, deterioration, substitution and loss
in transit is prevented.

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