There is a need to replace aircraft components on flight line trainers with simulated units designed specifically for the application. The system discussed in this paper involves a primary and secondary flight controls trainer to teach maintenance and rigging the flight control system. This paper discusses a method successfully used to meet requirements utilizing commercially available parts to produce assemblies which for training purposes out-perform their actual aircraft counterparts.Simulation techniques included: Use of reduced pressure hydraulics, substitution of electrical drivers and generation of synthetic signals to test equipment. Realism, system functionality and electrical and mechanical interfaces are not compromised. Benefits were cost savings, schedule improvement and greater safety.