You have a lot of options for building your home flight simulator.
You can use Styrofoam for the body panels on a cockpit enclosure.
The sturdy frame is made from plastic PVC pipe.
Add some paint and make it look awesome.
Styrofoam is a trademark of the Dow Chemical company.
Specifically, this is extruded polystyrene, or XPS.
It's insulation. It's lightweight, cheap and available at home improvement stores like Lowes and Home Depot or maybe your local hardware store.
Here's a closer look. It may be covered with a thin layer of protective plastic.
See what it looks like when you break it apart.
XPS is easy to cut with a common box knife. No power tools are required.
Don't try to cut all the way through the sheet the first time.
Cut about a third of the way down,
then cut again a little deeper.
Cut a third time completely through.
See how smooth the cut is when you use a new sharp blade on your box knife.
Compare that with this cut. We tried using a dull blade and it just ripped through instead of cutting it.
The blue XPS is Styrofoam from Dow Chemical. The pink sheet here is also XPS, but it's manufactured by Owens Corning. They have their own name for extruded polystyrene, they call theirs Foamular.
You may be hesitant to build things with pink foam, but after you paint it, nobody will know the difference.
In part 2 of this video we will show you a different type of foam insulation you can use on your flight simulator.
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