When homesteader and TV personality Eivin Kilcher set out to build a backyard airplane cockpit for his children, he didn’t just create a toy—he engineered a DIY flight simulator powered by real motion control technology. Proudly sponsored by Progressive Automations, the PA-HD2 linear actuators provided the power, stability, and precision needed to move major components of the simulator safely. For anyone interested in DIY engineering projects or integrating linear actuators into backyard flight simulators, this project is the perfect blend of creativity and practical innovation.
Project Overview: From Airplane Shell to DIY Flight Simulator
The backyard flight simulator’s journey starts with an old, salvaged airplane hauled home with a plan that was still evolving: maybe a playhouse, maybe a teeter-totter, maybe something in between. With help from his long-time friend, Holland, Eivin began transforming the salvaged airplane shell into an educational engineering project that is safe to touch and genuinely interactive for kids!
Eivin and Holland tackled the big early challenges first: rounding off sharp edges, adding structural reinforcement, and—most importantly—mounting the airplane so it could pitch and roll like a real aircraft. After experimenting with balance points and building a heavy-duty base, they fabricated a multi-directional hinge assembly that allowed the fuselage to tilt forward/back and side-to-side. That hinge became the foundation for turning the airplane into a believable backyard flight simulator experience.
Driving Motion Using PA-HD2 High Load Linear Actuators
Eivin initially tried using salvaged actuators from a hospital bed; however, these electric linear actuators could not properly handle the load requirements of his DIY flight simulator. He then reached out to our team for industrial linear actuator solutions, power supplies, and speed controllers to make the DIY flight simulator work. Our team recommended the PA-HD2 High Load Linear Actuator as this model offered the features, ratings, and specifications that matched or exceeded Eivin’s DIY flight simulator requirements:
· Ingress Protection: IP67 (Waterproof)
· 12 VDC operation, 14 A current draw
· Force options: 2023 lbs dynamic, 2698 lbs static
· Stroke length: 10"
· Full load speed: 0.24"/sec
Besides a higher force rating to handle the high load requirements of Eivin’s DIY flight simulator, our PA-HD2 model also has a higher ingress protection rating for better dust and waterproof protection in outdoor environments. The IP67 rating represents being dust-tight, rated for submersion in water up to a depth of 1 meter for 30 minutes. Stroke length options listed for selection on our website are for off-the-shelf units available for shipping right away; however, custom orders can be processed by contacting our team. Eivin installed three PA-HD2-10-2000-N-12VDC High Load Linear Actuators in total:
· One actuator for nose-up / nose-down motion (pitch control)
· Two actuators moving together for wing tilt (roll/bank control)
STEM Project Balances Engineering & Interactive Educational Play
Since small switches can’t handle the high current of the PA-HD2 High Load Linear Actuators directly, Eivin also designed his own control logic using micro switches and relays to enable high current control using low current controllers. The micro switches trigger relays, and the relays switch the power needed for the actuators. Speed controllers offered the option to manage motion speed for kid-safe operation when necessary.
Besides the visual presence and excitement factor for kids, it’s educational play with hands-on learning. The simulator turns basic flight concepts into physical cause-and-effect. Pulling back the control wheel causes the nose of the DIY flight simulator to rise while the fuselage rolls when you bank left. Kids naturally start using aviation language (“pull up,” “level out,” “stall alarm,” “runway three”) while understanding how motion changes the aircraft. As a STEM project, this hits multiple learning areas at once:
· Mechanical design (hinges, pivots, bracing)
· Electrical basics (DC polarity, switching, relays)
· Motion control (actuator direction, timing, speed limiting)
· Real-world problem solving (testing, failure, redesign)
And most importantly, its engaging, interactive, and visually realistic nature encourages kids with a desire to keep “flying.”
Project Results: A Backyard Flight Simulator That Actually Flies
After a year-long pause and a full redesign around stronger components, the build finally reached the moment that mattered. The kids climbed in, grabbed the controls, and the DIY flight simulator started moving those on board like the motion of being in a real airplane!
Even with a few real-world “first test” hiccups (like a weld breaking right before showtime), the project proved what quality motion components can unlock. The PA-HD2 High Load Linear Actuator setup delivered the power, durability, and versatility needed to make the DIY flight simulator movement real—without switching to complex hydraulic systems. The result: a real airplane body that can tilt dramatically—enough to feel exciting but controlled enough to stay practical for play.
IN SUMMARY
Eivin Kilcher’s DIY flight simulator is a perfect example of how the versatility of high load linear actuators like the PA-HD2 can bring ambitious ideas to life. Whether you're building a backyard flight simulator or creating a custom motion project, reliable linear actuators can turn a fun concept into a fully working system.
Thank you, Eivin Kilcher, for sharing your project with us! Check out his channel to keep up with his latest updates!
If you're exploring heavy duty linear actuator solutions for your next automation project or wish to discuss our products further, please feel free to reach out to us! We are experts in what we do and will be happy to assist however we can.
sales@progressiveautomations.com | 1-800-676-6123