Departure!

With all the components painted, it was on to upholstery! A sewing machine is not my most favorite piece of machinery, actually sewing is my least favorite activity that we do. Fortunately, we don't get to do it all that often! You can't actually see it clearly in the pictures, but we also added a magazine pouch, in-case they need it!

 All in all, it is quite a simple little set.

And this is approximately what the final comp will end up like. If it was lit properly, and the tarmac didn't have our screw cabinet sitting on it, I'd believe it was shot inside a plane!
8)
JWO

De Plane Boss De Plane!!

The arm rests were the next job to be tackled! We're only making 3 in total, as any more would be completely out of frame. And if they actually need anymore seating than we built, they have the option of shooting plates, and assembling them in post-production.

Each arm-rest was comprised of 4 pcs of 1/2" MDF, laminated together.

Once the glue had dried, I ran a 1/2" radius cutter around all the edges, just to soften them a little.

 While I was setting up our Techno cnc for the rest of the seat parts, Jody vac-formed .060" PETG over all 3 arm rests. She did this so we could cut the tops off the pull, and use them as arm rest pads on the tops of the arms.

The seat bases were cut from 3/4" plywood, edge sanded and filled to be smooooth!
We're actually only making 2-half seats! One will have a seat cushion and 2 arms, and the one in front of that will have 1 arm, a seat back, and no seat cushion. For sure this must be an economy flight :)
8)
JWO

I'v got my boarding pass ready!

 Next on the chopping block was the wall section. This section just has 3 windows in it. In the concept sketch, there is only one window that the actor is looking out of, but we added a window on each side so that light could come through, and look a little more real in the final image. These probably will never be seen, but you never know in the end! This was cut from 3/8" flexi-ply for easy bending.

The curved rib supports, and the wall stands were cut from 3/4" plywood for strength and weight. I also cut in a curved slot, so they could sand bag the bottom to hold it firm on the ground. Nothing worse than your plane falling in on you when your flying!

 The recessed wall panel, as well as the 3d window bezel were assembled. Again, the recessed panel was cut from flexi-ply, and skinned in .060" styrene for a smooth face finish.

Once they were all assembled, they got air nailed to the back of the curved wall section.

With the large curved wall section also skinned in .060" styrene, the wall is definitely starting to come together!!

 With all of the inserts, and window bezel assemblies in place, I sprayed the entire unit in a rubberized texture spray. This will add a mild texture to all the smooth wall panels!!
8)

JWO

Welcome to Westjet!

Well a generic version of a similar plane....................
This job is for a print campaign. I don't have any idea of what the final image will be used for, but I don't really need to know either! I was sent a PDF sketch, and we'll basically build everything in the sketch, plus a little bit more for safety. That way they have a small amount of room to move the camera, depending on how they lens it.

Our client needed a small section of jetliner interior. The image will be a tight shot of a person looking out the window.
I did a google image search of airplane interiors, and downloaded a ton of reference material, including some 3d cad renderings.
Very little of this build will be full on 3d cnc machining, but more just flat cut elements.

In order to make sure we were all on the same page, I 3d modeled what I thought we should be building, based off of some back and forth phone calls. With approvals signed off, I set to work exploding out the 3d computer model into flat panels for cutting on our Techno cnc.

And after a while of working the file, I was able to layout all of the pieces in 2d. The biggest pain was the curved wall, making sure that everything was going to work together, after it was flat cut, and wrapped into the curved shape. As you can imagine, it was more difficult than I first anticipated! Especially because the curved wall is made up of a few different laminated layers, that all have to work together, especially the actual window bezel, which will be 3d machined.

The window bezel was brought to life in 3d through Aspire alone. The vectors were created in Corel, as was the whole 2d portion of things, but Aspire was the fastest way to get from 2d to actual 3d geometry!

The bezel has a dropped lip on it, and this will become the edge that we'll use to fasten it to the curved wall section. We only need 3 windows for our plane section.

The actual bezel I cut from 3/4" mdf. An inexpensive material, with just the right thickness! All 3 only took about 25 minutes to cut with a 1/4" ballnose cutter.

Due to the relatively thin side profile, I also cut a flat plate from 1/2" MDF. This will get fastened to the back of each window to beef it up. This plate also has a rabbet cut into it, allowing us to slip in the window shade. It won't be the full shade, just what you would see from the inside, with it in the upright position.

The only other 3d-carved portion of this build was the seatback, and upright tray table. These I actually drew in Hexagon, and brought into Aspire. Only because I had drawn them for the approval render, although they would have been pretty quick to model in Aspire alone!

No headrest tv's on our bargain basement flight booking!

With all the carving complete on the 3d side of things, we sprayed the MDF parts wth 3 coats of a sanding sealer, then 2 coats of a high build primer. These will get a slight texture coat sprayed on them, but I wanted the base finish to be the best it could be, before the texture!
8)
JWO