debolestis

I was working on 5Way switch last few days. Sergey_Pe pointed out to me that I cannot simply wire Alps switch like TM switch because diagonals will not work. He gave me this schematics: Problem for me was that everything is so tiny and I have to use SMD components for the first time. I hope it will work. I uploaded PCB to OSH Park. Diodes that I used are 1N4148 SOD123 package. It could be used with holder that I uploaded to my Sapeways store.

Thank you Sokol, great find!

Spring are quiet for now, but I should probably use grease.

Here is joy tester: I received new springs. This is spring dimension: I ordered in 3 different wire thicknesses: 1,0, 1,2 and 1,4mm. 1,0 is OK for plastic grips but not for Warthog because it is too heavy. 1,2 is much better, almost the same feeling like in NXT mod. 1,4 I didn't tried yet, I think that thickness is too much. I installed MFG sensors and controller. It is very smooth joystick now, no center bump, but it is very light in the center, heavy grip doesn't help here. All in all I am happy with this, If you tried NXT gimbal, this is more or less the same. Save

Great work, I love it!

Part 2 Then goes main shaft, in previous photo you can see it, but in wrong direction. I corrected that and installed m6x35 screw with washer and nyloc nut. Tighten that firmly, there souldn't be any "yaw" in main shaft. If there is some then you haven't tighten it. Use tools from first photo. Then tighten gimbals to enclosure using 2 M5x30 and 2xM5x35. Spring are not good, they are very light, but they are all that I had. I ordered a new set. You can see where two springs are scratching against M5 screws and nuts. That is first print. I corrected that and now there are slots for nuts. M5x30 are used in that position. On opposite side M5x35. And in the end rubber boot. The one that I had was damaged, but I kept one from old Thrustmaster Top Gun 2 joystick. It is on the right, original is on the left. They are of same diameter but slightly different shape. Top Gun 2 ring does not fit on Cougar. I'll polish original ring when I find some time. It fits! And here is fully assembled joystick with my new B8 grip. Everything works as planned. I made only one mistake, but that is corrected. I'll get new springs in few days and we'll see how it feels, but at the moment I am very happy with it, everything moves smoothly, no center bump. Save

Part 1 This will be a longer post. Now I'll explain how to install my Cougar gimbal. You'll need some tools, this is what I used. Not everything in a box was used only screwdriver and bits for it. There should be 4 printed parts. In photo I already installed female mini din connector. First I'll explain how to install ball bearing. They all fit slots very tightly. But with following trick you can do it. At first place bearing on table and press the printed part on it. Bearing will enter the slot a little bit. You can see that bearing on photo bellow on the right. Then put M6 screw trough it and on the other side put another bearing that will act as stop for m6 nut. Then simply tighten and it will easily go into slot all the way. Untighten and remove left bearing, screw and nut. Repeat procedure on second part. Now install m3x20 screws that will hold a sensor. Tighten bottom nuts, top nuts are standoffs for sensor. Then install 2 ball bearings. Both bearings will not go all the way into slot, they will be 1mm outside of slot. Both are installed from inside. It would be better to use cap hex screws, with hex wrench it is easier to tighten them. Then install M4 nuts like on photo and tighten the screws. Then install 2 M6x20 screws into slots and tighten the nuts. Don't install washers. Install two M4s here as well: Then like in picture, I made two mistakes: Installed: Now install sensor on this position. This sensor is MFG digital sensor. I visited Milan's factory and he gave me sensor and controller, but I'll write more about it in next few days. Use M3 screws to tighten the sensor, I used cube magnets, that is not good solution, I am looking for better magnet, I'll let you know when I find it. I'll probably use ring magnets and sensor will be a bit closer. Then we need to install gimbal into enclosure. I first installed 4 M5x8 screws. They are just for decoration. Gibal can be installed in two directions, it is up to you. Don't tighten the gimbal yet. First install second sensor like in this photo: Save

I uploaded Cougar gimbal in my store. There are 4 parts, total price is $89,84. This is for white plastics, painted parts cost 1$ more each. That is the cheapest that I could do, I take 2$ per part, all of the rest goes to Shapeways. Other parts are: 4 x 696ZZ ball bearings. Screws and nuts, please use stainless steel nuts and screws, only exception are two M6 nuts, they should be made from regular magnetic steel. - 1 x M6x35 + nut - 2 x M6x20 + nuts - 4 x M5x30 + nuts - 4 x M5x8 + nuts + washers - this is just for decoration - 4 x M4x25 + nuts - 2 x M4x35 + nuts - 4 x M3x8 - 2 x M6 steel nuts - 2 magnets, D=10mm, d=5mm, h=5mm - R10x05x05ND-N45 - 2 Sensors. I used GVL224 sensors, you can contact him, THIS is his thread. You must tell him that sensors are for +/-20 degrees. -4 springs like in photo below. Wire thickness is 1,2mm. -Cougar enclosure. If you don't have it you can make one yourself with this template: B Part-1 $22.35 Part-2 $16.27 Part-3 $35.16 Part-4 $18.65 Save Save Save Save Save

I corrected errors on X-Fighter to Warthog/Cougar tailpiece. HERE Enter code: SMALLBIZMONDAY at checkout and you'll also get Free Shipping and 25% off. Today only.

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I am going to create tailpiece empire!

THIS IS Suncom throttle 100%.

Check this LINK.

OK, I understand. This switch is in X-fighter at thumb position, more or less. It is 12mm tactile switch. This is 5way switch: It is almost the same shape as yellow switch above. It would be easy to install 5way on thumb position. If you are beginner, then I think it is best option for you. I can make knob for it if you want, but first you have to test if fits. If it doesn't fit we'll see if something else can be done.

I am so sorry Thadiun Okona for that. I ordered acrylate only once and it was great. Maybe there is difference in European and US printers. What you have is terrible. Here is my DMS. It feels very smooth, some lines are visible, but result look like factory finish. Without flash

Great work. Awesome!!!

It is 6x6x4.3 tactile switch. Here is the LINK. It can be any other that fits this dimensions.

Unfortunately not. I was thinking about that but there simply no room inside. But trust me, wiring hall sensors will same as wiring potentiometers, and hall sensors are so much better, you'll see. I designed this with "standard" hall sensor PCB that can be easily found here on forum from GVL224, DVik, and in future from MFG. Save

Capacitor must be soldered, it will probably work without it, but sometimes crazy button response can happen. Resistor on the left is not necessary. It is only necessary when shift registers are daisy chained, but it will not happen inside of a grip.

I mentioned before that I am working on Cougar gimbal. I acquired Cougar enclosure and started to work on new gimbal. It is similar to NXT gimbal but for a fraction of cost. I know that this comes maybe 10 years to late, but it will be possible to use this on custom enclosures. I'll provide a cutting template for custom enclosures. Than again maybe there are still a few Cougar owners who are stuck with crappy gimbals and would like to upgrade. Idea is to print 4 parts and add ball bearings and few screws and nuts to it. I was worried on M36x2 threads, I have never printed threads before but fortunately everything works like charm. Sorry for bad photos, I worked in the evening. All parts seem to be very strong. Ball bearing are not going easy into their slot but with few tricks they obeyed. 4 ball bearing are needed. I was able to print slots for M4 nuts. I don't have proper springs yet. These that I have are to wide any very light, just for test at the moment. I still have to buy few more screws. In the end everything sat in place as planned. Whole gimbals are bigger than NXT, but It must had been done like that. I still have to see how strong it is when I find proper springs. I made mountings for sensors that have 34,5mm hole spacing. Sensors like GVL224 and others produce. I'll post test results soon. Planned price for complete gimbals is around 75$. Save Save

A few parts arrived recently. First let's see X-fighter tailpiece. I ordered it in orange color, and it looks really great. I have only plastic Gardena nut, I'll buy a metal one soon. I made 2 cuts on it, tailpiece couldn't go through without it. Photos aren't of best quality, sorry for that, I worked in the evening. Then I saw that I made error in my drawings. I misplaced mounting holes. Also shaft is maybe 0,2mm to wide. I am so sorry for this, I usually triple check, but mistakes happen and it can be fixed. You can see white marks on tailpiece, next to mounting holes. There should be holes. I drilled new holes with battery drill, it was easy. I mentioned in few posts before that capacitor on shift register is not needed. It is not true. I had some crazy button response when I put everything back together, I thought I had short somewhere, but it wasn't the case. When I added 100nF capacitor, then everything went back to normal. Than I put everything back together. Shaft is just a bit to wide, but is not a problem. One more for my collection. Again, I am sorry for this error, I'll correct it as soon as possible.

I don't have any solution for thumb switch on X-fighter. This will have to be improvised.

Thank you for great feedback. I could go with thinner walls on nylon tailpiece, but I am not sure how will that go when used for a longer period on Warthog. Holes should be 2mm. It sometimes happens with nylon printing, small holes are sometimes printed narrower. I think it is best to leave it as is, nylon is very easy to drill if necessary. Save Save

Suncom stick is more complicated due to internal construction. I have tailpiece made and tested and it works OK. You can buy it HERE. Other thing that is needed is new PCB that goes inside grip. I am working on it.

I can redraw PCB in Eagle CAD using through hole components. It will take a few days. Good thin OSH Park accepts Eagle directly no need to convert to gerber files. I'll try to do it as soon as possible.