Hawkeye60 Posted September 25, 2016 Posted September 25, 2016 I have wanted a set of helicopter controls ever since getting the Gazelle. The commercial offerings were too costly. After searching the forums, I found this, https://forums.eagle.ru/showthread.php?t=56757&highlight=flcs+conversion Using this info and diagram, I have created a cyclic, and have the collective 75% done. My goal was to keep the cost as small as possible. Having been flying sims for thirty years or so, I have collected a fair share of joysticks and throttles. Never could bring myself to junk them. So for this project, I have used, Thrustmaster FLCS handle Flight stick pro base (the one with strong springs) Leo Bonder BU0836A D-sub connectors from radio shack 90 deg brass pipe fitting Brass adapter for top of base handle shaft 4 foot telephone cable with 20 strands (small wires) Heat shrink tubing CV boot for gator Pvc pipe and fittings The project took a couple of weeks to complete, working off and on as time allowed. I plan to update the axes to hall sensors. The photos are prototype #1. I have quite a long horizontal "extension" at the top to allow use with my VERY comfortable chair. I will change the shaft in the future to a better shape, and paint it. The small d-sub connection at the bottom of the base is for the collective to come. I also added weights to the tube to balance the cyclic. The base is bolted to the foot rest of the saitek pedals which provide stability without needing a special mount. So... how does it work? It feels like I got 30 hours of flight training, overnight, while sleeping!:D The difference is amazing! Maneuvers which were difficult before are now "almost" easy. Holding a hover within a 10 foot "box" is now possible without much trouble in the Gazelle. Was tough before. I will post the collective photos and info when done. It has been a fun project. Total cost, not including the joysticks, about $80.00 to $100.00. This includes all parts for the collective as well. Any questions, feel free to ask. "Yeah, and though I work in the valley of Death, I will fear no Evil. For where there is one, there is always three. I preparest my aircraft to receive the Iron that will be delivered in the presence of my enemies. Thy ALCM and JDAM they comfort me. Power was given unto the aircrew to make peace upon the world by way of the sword. And when the call went out, Behold the "Sword of Stealth". And his name was Death. And Hell followed him. For the day of wrath has come and no mercy shall be given."
aeliusg Posted September 25, 2016 Posted September 25, 2016 Nice idea to attach it to the pedals footrest. Great mod for what you spent.
Sokol1_br Posted September 25, 2016 Posted September 25, 2016 (edited) Good. Job. I always had curiosity to know how is this early Tm PFCS (metal base case) gimbal - the first Tm made joystick, seems in garage of brand founder. https://forums.eagle.ru/attachment.php?attachmentid=148866&d=1474814588 Their gimbal is in aluminum parts? Looks better/sturdy than... Cougar gimbal. :) Edited September 25, 2016 by Sokol1_br
JG14_Smil Posted September 26, 2016 Posted September 26, 2016 Pedal base is cool as heck. Seems like a lot of leverage on the plastic parts for the cyclic. Best of luck on your build. I have scrap TM parts laying around here... I think the production PFCS was plastic. Cougar is potmetal (aluminum).
Hawkeye60 Posted September 26, 2016 Author Posted September 26, 2016 Pedal base is cool as heck. Seems like a lot of leverage on the plastic parts for the cyclic. Best of luck on your build. I have scrap TM parts laying around here... I think the production PFCS was plastic. Cougar is potmetal (aluminum).The base set up in very stable. I have no movement or flexing at all. It also allows me to move it out of the way very easily to fly planes. The PFCS base is steel. I looked inside the base of the F22 FLCS, (plastic) which has a larger foot print. to compare the spring set up. The PFCS has extra screws by the springs which increase the tension. (see photo) Also, with a smaller foot print, it fit perfectly on the saitek plate. I used a brass adapter, not shown in the photos, on the base shaft which extends almost to the bottom. Have a hole drilled though the fitting and a screw to prevent twisting and to secure properly. This seems to provide a very strong connection even if the shaft is plastic. So far it works perfectly. I am thrilled with how it came out. Back to the collective build! Plan on having a throttle, two axes pots, a hat switch, two 2 way rockers and a 2 way mini toggle switch with one momentary position. Will update when ready. Thanks for your comments. "Yeah, and though I work in the valley of Death, I will fear no Evil. For where there is one, there is always three. I preparest my aircraft to receive the Iron that will be delivered in the presence of my enemies. Thy ALCM and JDAM they comfort me. Power was given unto the aircrew to make peace upon the world by way of the sword. And when the call went out, Behold the "Sword of Stealth". And his name was Death. And Hell followed him. For the day of wrath has come and no mercy shall be given."
Sokol1_br Posted September 26, 2016 Posted September 26, 2016 (edited) I think the production PFCS was plastic. Cougar is potmetal (aluminum). PFCS Mk.I and latter models (Mk.II, Top Gun) is that is in plastic (except that version with F22PRO base.. something "X"). Cougar is ZAMAC (pot metal used in door knobs, jewelry...), why broken/worm out easily. :P This original PFCS sees the most well done gimbal from Tm. :) Edited September 26, 2016 by Sokol1_br
Hawkeye60 Posted September 26, 2016 Author Posted September 26, 2016 Good. Job.Thank you Sokol1_br I need to thank you personally for posting the wiring diagram which inspired this project. I also got to blame you for the mess on the table when the wife complained.:D I need to thank you AND apologize to you for that at the same time!:cry: Sorry! Could use some help with the hall sensor installation. I have two sensors from Leo bonder but no magnets. Thanks again. Having fun building. "Yeah, and though I work in the valley of Death, I will fear no Evil. For where there is one, there is always three. I preparest my aircraft to receive the Iron that will be delivered in the presence of my enemies. Thy ALCM and JDAM they comfort me. Power was given unto the aircrew to make peace upon the world by way of the sword. And when the call went out, Behold the "Sword of Stealth". And his name was Death. And Hell followed him. For the day of wrath has come and no mercy shall be given."
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