All Products Made In The U.S.A 
Manufacturing Capabilities:  (Cost Effective Solutions)
 | Highly Versatile - Knowledgeable - Solution Orientated. |  | Small Or Large Production Quantities Capable. |  | Metal Foundry Or Plastic Forming & Molding Capabilities. |  | Rapid Prototyping Capabilities. |  | Product Duplication Is Non-Destructive And Accurate. |  | Fast Turn Around To Meet Customer Schedules. |  | Cost - Quality - Schedule - Customer Satisfaction. |
High Rev Simulators manufactures F-16 flight simulators and controller sticks throttles yokes along with electronic boards and strain gages. HRS is a manufacturer of flight simulators that are at times called cockpits enclosures devices boxes platforms trainers and sims. HRS also manufactures ejection seats and can be real creative when a special projects is needed by a customer. We are a one stop shop and can supply and meet a customers needs at economical pricing.
All simulators and associated products start with either real parts, tools or drawings. 
This F-16 is a Lockheed Martin Master Simulator Tool delivered to HRS with the original Lockheed tooling tags still attached. High Rev Simulators is reproducing very accurate sets of flight simulator fuselage and cockpit instrument structure. The HRS F-16 flight simulator cockpit fuselage and internal instrument structure components were produced from one of Lockheed Martin's flight simulator master tools and real f-16 parts. The flight simulator cockpit instrument structure parts were made from real F-16 parts. To keep the costs to a reasonable level - we made conscience decisions to make them in fiberglass but still hold the line in accuracy to the real parts. What you have is the same cockpit instrument structure panel fidelity that you find of the real - high priced part.
We at High Rev Simulators even duplicated the 2 inch thick interior cockpit side wall gap by creating the cockpit side wall covers and put the gray hair cell plastic sheeting over the fiberglass. To add to "The Look" we then put in the screws and washers that should be at each frame station.
HRS only allowed one exception to where the mating of the side consoles and the left/right front instrument auxiliary panels interface. Changes were implemented in this area to allow cost saving producibility for a more simple and stronger mating of the side consoles and lower auxiliary panels. F-16 FLIGHT SIMULATOR MASTER PART CREATION: This original simulator enclosure box tool was in rough shape and need to be sanded, filled and spray primered before the real work could begin. After fill and smoothing primer was added the contour sanding begins - checking with blade templates to get the unit as close to the real aircraft contours as possible. 
 | F-16 FLIGHT SIM MASTER MOLD RELEASE AND JELL COAT:
The edge breaks are applied to separate the sides of the fuselage and mold release paste wax is hand rubbed into the unit approximately 8 to 10 coats. The spray-on-release agent (green) is then sprayed and allowed to completely dry and the Jell Coat is then applied. |


 | F16 FLIGHT SIMULATOR COMPOSITE FIBERGLASS:
Fiberglass and wooden external reinforcements are added to the jell coat surface to complete the molds and prevent warp age of the mold. The master is removed from the mold and the mold surface is prepared for casting. Each fuselage half is cast up using industry standard fiberglass techniques. The fiberglass fuselage pieces are left in the mold for several days to fully cure before they are removed. |

 | F-16 FLIGHT SIMULATOR PRODUCTION PARTS FABRICATION
After removal from the mold the fuselage halves are prepared and fitted together before the interior fabrication phase can begin. Using a similar process as described above for the simulator fuselage parts, the interior cockpit parts are fabricated and assembled for inside the fuselage installations. NOTE: In the first picture on the left is a comparison of HRS's F-16 on the left to HRS's F/A-18 on the right side of the picture. |
 | F-16 FLIGHT SIMULATOR FLOOR AND BOX ASSEMBLY:
The main floor duplicated from the original F-16 simulator floor along with the instrument and rudder pedal box. Each assembly detail part is cut and air gun nailed along with the instrument and rudder pedal box. If you notice the outboard edges (Left and Right) of the front instrument box sides will slide down over the 2x6 inch main floor sides and is secured to the side edges of the main floor with bolts and tee-nuts for easy removal. |  | FUSELAGE FLOOR:
Our flight simulator floors is made to exact dimensions of 2x6's and 3/4in exterior grade plywood. The floor is covered using gray hair cell plastic sheeting bonded to it. The floor is attached to the fuselage shell using carriage bolts/washers/nuts in the Fuselage Support Flanges and the 2x6 floor walls. |


 | F-16 FLIGHT SIMULATOR INTERIOR INSTRUMENT PANELS:
The Interior Instrument Panels are made much the same way as the fuselage using standard fiberglass processes. Fabrication molds are molded from a master that was a real part. Because of the complexity of the interior parts HRS uses a process of hairing with fiberglass to allow fiberglass to be laid around difficult bends and curves. Its a split on whether to vacuum mold each part and driving cost or getting the same high fidelity strong part for about half the cost using the hairing technique. |



 | F-16 FLIGHT SIMULATOR FINAL ASSEMBLY:
Instrumentation is assembled and tested. Depending on the fidelity requirement these can be up to full mil spec standards. Instrumentation, switches, gauges and flight controls are then installed to meet the customer exact specifications.
Exterior And Internal Structures: All flight simulator fuselage and instrument panel structures are fitted and installed using Bolts/Washers/Nuts. NO Self-Tapping Screws are used - NO Exceptions.
Rear Aft Intermediate Bulkhead: HRS's flight simulator bulkhead is located just aft of the cockpit and is made of 5/8in exterior grade plywood with gray hair cell plastic sheeting bonded to it. The flight sims bulkhead is attached to the upper and lower fuselage bulkhead structure with T-nuts and black Allen head bolts for an added touch.
Fuselage Stability Supports: HRS's simulator supports are 2 low profile bases bolted to the notched fuselage floor and covered with hand laid Gel-Coated fiberglass shrouds. These stability supports blend and streamline the fuselage contours at the front and rear. This attention to detail really adds to the touch of a beautiful F-16 flight simulator.
Paint: Interior and Exterior simulator structure is painted in flat grays and blacks using tough automotive type paints - Not paint from the local Home Service Center. |

F-16 FLIGHT SIMULATOR Fully Assembled and Flight Ready - The cockpit is ready for final testing, QA and delivery to the customer. The F-16 is a hybrid built for Evans and Sutherland and has two monitors install in the front instrument panel. 
Customer Requested Design Changes We at High Rev Simulators will make custom design changes to our flight simulators at your request. Provide us with your requirements and lets see what can be developed. Call HRS for any additional information and pricing: (661) 947-6820 Other Products: F-16, F/A-18, F/A-22, F-15, RQ-1 flight controls, unmanned aircraft vehicle, desktop sticks, hotas controls, hotas stick, grips, stick, stick grips, stick heads, joysticks, joystick grip, joystick head, stick quadrant, hotas throttle, throttles, throttle head, throttle grips, throttle quadrant, cyclic, collectives, flight yokes, yoke mechanism, precision flight controls, rudder pedals, rudder, pedals, strain gages, strain gauges, sensors, usb, switches, precision hall effect sensors, usb, boards, electronics, micro electronics ejection seats, aces ejection seat, naces ejection seat, flight trainer, flight simulators, flt sims, cockpit, simulator, sims, trainer, box, device, enclosures, platform, simulations desktop, weapons trainer, flight navigation procedures trainer, mission trainer, flight training trainer, cockpit trainers, other training device, otd, p.c.a.t.d, pcatd, motion platform, flight simulator box, training and simulation, aircraft training device, avionics trainer, flight training devices, instrument trainer, synthetic training device, synthetic fntp part task trainer, ptt, instrument displays, display bezel, avionics, aircraft, airplane, aviation, bomber, fastjet, fixed, wing, helicopter, helo, copter, jet, prop, plane, rotary, wing, rotary wing. | | 
Tel: 661 - 947 - 6820 Fax: 661 - 947 - 0449 Email: sales@hirevsims.com
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F15 F-15 Strike Eagle F16 F-16 Falcon F18 F-18 F/A-18 FA-18 FA18 Hornet Super Hornet F22 F-22 FA-22 F/A-22 Raptor F14 F-14 Tomcat F117 F-117 Night Hawk Stealth Fighter F35 F-35 JSF AV8 AV-8 Harrier A/AO-10 AAO-10 AAO10 A10 A-10 C Wart Hog A-10 Thunder Bolt II 2
UAV UCAV RQ1 RQ-1 Predator RQ4 RQ-4 Global Hawk RQ8 RQ-8 Fire Scout UCAV X45 X-45 UCAV X47 X-47 UCAV
AH64 AH-64 Apache RAH66 RAH-66 Comanche AH1 AH-1 AH1Z AH-1Z Super Cobra AH6 AH-6 Little Bird
UH60 UH-60 Black Hawk SH60 SH-60 Sea Hawk HH60 HH-60 Pave Hawk HH53 HH-53 Jolly Green Giant CH46 CH-46 CH47 CH-47 Chinook OH58 OH-58D Bell Kiowa Warrior TH57 TH67 Trainer TH-57 TH-67 Trainer
B1 B-1 Bomber Lancer B2 B-2 Spirit Stealth bomber B52 B-52 Bomber Stratofortress E3 E-3 AWACS C130 C-130 Hercules C-130 Specter C141 C-141 Star Lifter C5 C-5 Galaxy KC135 KC-135 Tanker KC10 KC-10 Tanker V22 V-22 Osprey P3 P-3 Orion
Minuteman Missile Peacekeeper ICBM
M2/M3 Bradley M1 Abrams Hummer M113 MLRS Patriot Missile
Rapid Prototyping Rapid Reconfigurable Rapid Deployable Sims
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