AndreZero

Sure, Let me know if this gives you what you need This one doesn't have a bracket like the NWS switch so the hollow under the head isn't necessary. The recess for this is shaped like the "leg" on the button though I didn't measure the recess where it makes contact with the microswitch because it is identical to the other button. In fact, I took the button I ordered from shapeways and it fits in there perfectly.

I got the new button from Shapeways. It's pretty close but needs some minor modifications. Here are the original and the new one. The original has gaps that accommodate the prongs that hold the microswtich in place for the NWS button seen here: Since the other button doesn't have those prongs, I figured I could just swap them out but the head of the button is ever so slightly too big so it fits but the first time I press the button it gets locked in place. I filed the perimeter of the head of the button (thankfully I had it printed in plastic so that was easy) and then it fit! So it works but could use some tweaking. Not sure if it is a necessary feature but the notch isn't in the final print.

Cool! I've ordered it in plastic. If that works out well I may re-order a metal version. Thanks!

Here are some pics and measurements. let me know if you need any more. I suspect the trickyiest part will be the inner whole that locks onto the microswitch. http://imgur.com/a/0v7eH

debolestis, Do you think you could model the s1/s2 button? I'm missing an NWS button on my Cougar stick but the microswitch under it is still working. I'm hoping to be able to buy a replacement from your shapeways shop. Thanks

I managed to get my throttle dead space out using the technique described in your updated calibration video. Since I am using the throttle plugged into the stick, along with the HOTAS Cougar Control Panel, I found DIView gave me inaccurate numbers. It appears that the stick stores the calibration data and will report different values to the pc. So instead of using DIView I had to use the Cougar Control Panel. These pictures may clarify what I mean. The range in the cougar control panel is 0 to 571. With my current placement of the magnet ring, that is limited to 134 to 560. DIView shows 0 and 255 for raw values at those points. One other minor point is that the loss of precision means I sometimes register as being on the other side of my detents. I'll have to play around and see if I can adjust for that.

Can shapeways print rubber? I'm fairly sure this friction pad is made of rubber and using plastic (or other materials) might not be a great idea...

Hi Miles, I got the parts you sent today and assembled them as shown in the picture. I've still got a fair amount of deadspace. Looking forward to the configuration video so I can see how much I can minimize that. Thanks Andre

Can you PM me and we can setup some evening next week? My in-laws are in town so finding time I can dedicate to troubleshooting is iffy right now but next week should be better. Thanks

I guess I should have been more explicit. I'm running windows 10 with the Thrustmaster Cougar drivers installed. When I go to the game controllers screen I see my Thrustmaster HOTAS Cougar listed and two buttons "Advanced..." and "Properties" The Advanced button only gives me one option, to select my default device. The Properties button does nothing... When I was running Windows 8.1 this button would open the HOTASView control panel but in Windows 10 it doesn't automatically open (I can manually open it though). I think I can use that to tune the settings, it just looks very different than what you showed in the video. I also think the HOTAS Cougar Viewer shows the calibrated value rather than the raw value so I don't know if it can be trusted for calibration purposes. I verified that I have the ring installed in the correct direction. The side where the magnets are visible is pointing away from the sensor (so the closed side is facing the sensor). When you say that the ring should be in the "forward position when the throttle is pulled back to idle", does that mean it should be reading 0 while in idle? Because with the stock pot, I'm getting the highest value when the throttle is back and the lowest when it is forward. Ok... just did a quick test with the stock pot and move the throttle in the opposite direction than it told me to while calibrating it. I thought it would not let me do this since for most values it knows max should be higher than min but it let me do that. And after calibrating it that way, the back (idle) position still reads the highest value. So long story short, I think (hope) I just need a way to see the raw values while I calibrate the hardware, then I can run the cougars calibration routine to calibrate the software. I think...

Hi Miles, I've got a couple questions about configuring the sensor. I can't find the windows setting you are using to get a reading so I was using the HOTAS Cougar Calibration routine. When I set it so that the sensor returns a 0 when the throttle is all the way forward, the ring prevents me from putting the base back on (it is positioned such that it is in the way). Are you calibrating this so that all the way back is 0? I suspect that the cougar software won't allow that... My second problem is the sensor range. When I set the sensor to read a 0 when the throttle is at one extreme, the sensor seems to be hitting the max reading (as reported by HOTAS Cougar Control Pane) with a fair amount of play left on the throttle. Am I installing this incorrectly? My third question is that your video doesn't show what to do with the yellow wire that is attached via a screw. I assume that is a ground wire and should be placed under the corresponding screw but it doesn't appear to be in your video. Thanks Andre