Building New Helo Cyclic Grip

[heloguy]

Just wanted to share my next project, as well as look for any advice. I was able to acquire an OH-6 cyclic grip, and want to modify it according to some H-60 pictures I've seen in some walkaround websites. Here's the original grip:

 

 

What I would like to do is the following:

 

 

 

 

In all, I see 25 total buttons.

 

My plan is to make this Warthog compatible, so I already see a problem with the number of buttons. If I can substitute some of the buttons for all eight ways of a POV switch, then I'm good, as the button total will be 17. If not, then I'm stuck with 21 desired, and 19 available, unless I'm mistaken about the max button count available through shift register.

 

So far, with buttons, I would like to replace the ICS/Radio rocker (I'm sure it's old)with a like switch, but will test it to see if it actually works with a meter. The rest of the buttons, I also plan to replace with what's in the pics. I need to take some measurements to see how big the switch bodies need to be (as well as how big the tail piece needs to be), but I'm definitely open to suggestions on where to find such switches. The biggest hurdles I see are adding the second trigger (mainly due to the modifications required), and adding the rocker switch for force trim release (ringfinger switch on the left side as pictured).

 

Also, what is the best way to PCB this beast? I do have a Warthog grip with a VKB adapter that I never use, but I'd rather just save that, and get something new and separate.

 

I'm also aware that just wiring the switches to a BBI-32 or something of the like might be the only option, but I'd like to save the USB port on my computer. It's not out of the question, but if I can make it Warthog (Shift register) pure, that would be ideal.

 

Thanks for looking, and any suggestions.

Edited December 20, 2018 by heloguy

[heloguy]

Small update to this: Per a suggestion by Sokol over at SimHQ, I ordered some parts from Thrustmaster (switches, and grip for the PCB), and some ALPS 8-way plus push switches.

 

I've also ordered some parts from Debolestis Shapeways store to use, so I'll see what I can come up with when it all arrives.

[TomVR]

you should consider photogrammetry scanning your original grip and just 3d printing a whole new one with the necessary holes and mounting points