We traveled back to Seattle in mid-March to test fit the mock-ups I had made. I wanted to make sure that everything would work before we built the actual components. Everything worked great with the exception of the scanner hood which was 1/16" too big each way. We also disassembled parts of the console to determine how best to light areas under the astrogator and the chronometer and also we removed the knee panels on the under backside of the consoles. It was important to understand what materials and areas we were dealing with because none of our replacement parts could be physically attached to the console. Here are a few photos from the March visit:
Here is the helm console with the mock-up for the control panel in place. The "mock-up" was a clear piece of plexi with the hole pattern printed on it. That way you could clearly see how the cut-outs in the control panel would line-up with the holes in the console. As you can see; everything lined-up quite nicely.
We also prepared sample boards to match the paint color and texture. Here is the sample board for the black console color:
Here is the mock-up of the hood which was 3-D printed. As you can see it was just a hair too big to fit down into the top:
Here is a close-up of the only remaining original rocker switches which are much more vibrant in color than they appear on screen. We matched these colors for the replacement switches. You can see on the right side the crude foam rocker switch that someone tried to make.
As before, we took this opportunity to continue our examination of every inch of the console.
During this visit we made our first installation on the console which was the micro switches near the bottom of the helm console. I have no idea the make of the original switches but these vintage replacement switches are Hetherington switches which is the same company who made the white & black push buttons seen throughout the ship.
Studying the inside of the console
We also replaced a number of missing screws so of course we documented the existing screws to make sure our replacements were identical