DIY HOTAS Modifications & Constructions

[Viper1970]

As a flight simmer since the past over 20 years and an enthusiast for military aircraft of all kind, I'm now going to built some HOTAS replicas for all my favorite aircraft. I have started this project a long time ago, back then with a universal full size pit for use with all kind of military aircraft from transport planes, over attack helicopters to fighter jets.

 

Sadly my RL always forced me to stop with this project, so I never was really able to finish it. For this reason I dropped the idea of the full size pit and changed to a VR-pit. The only thing I still wanted to have are the correct input devices for the type of aircraft I am flying. So I decided to modify some TM Warthog and Cougar Systems to replicate other types of aircraft.

I'm still at the beginning of this new project and wanted to know if someone else did such a thing allready.

 

My plan is to modify three of the new bought four Warthog throttles with other throttle handles and an AB-fingerlift to fit the F-14, the F-15 and the F/A-18. One Warthog still remains original for the A-10. I also have two Warthog stick bases, one will be left original and will serve as the side stick base, the other one will be modified with a self made gimbal system, an extension and used as center stick base. For the stick grips I will use the TM F-16/A-10 grip, the TM F/A-18 grip and the Virpil VFX grip. I also ordered 3 extra Warthog F-16 grips and one additional F/A-18 grip to use the hats, the buttons and the electronics for my own B8, F-15E, AH-64D and OH-58D stick projects. The throttle of a used HOTAS Cougar system will be modified with TM TWCS electronics to run as a stand alone throttle. To this throttle I will also add a nozzle control to use it with the AV-8B Harrier II. This way all devices are compatible and useable with the Thrustmaster TARGET software, I absolutely will be able to use with my systems. The rudder system is a TM TPR rudder, cause I think it is useable for jets and helicopters together.

 

The only things that will not be TARGET compatible, will be the DIY helicopter collective, the yoke and the multi engine throttle quadrant for the big birds like C-130 or C-17. As said I'm at the beginning and wanted to now if someone else already made such a conversion of thrustmaster equipment on his own and if how you did it.

 

P.S:

 

The handles and grips I wanted to use are either from older sticks like the TM X-Fighter or the Suncom Talon/Eagle or self made 3D-prints.

 

Edited January 30, 2021 by Viper1970

[Ala12Rv-Tundra]

26 minutes ago, Viper1970 said:

The throttle of a used HOTAS Cougar system will be modified with TM TWCS electronics to run as a stand alone throttle.

Some user forums offers that for 30€, 20€ more if you want a Hall sensor.

[Viper1970]

Thank you for the advice. I wanted to use the TWCS electronics to still be able to use the TM TARGET software for programming the throttle, but as a stand alone device without the need of the still connected but useless stick base. I also know those stand alone solution like Arduino, TUSBA or any other, but all of them gives you only the ability to use the throttle as a standard DX-Device. For sure you can use Joystick Gremlin with it, but that's not so manifold as the options TARGET gives you.

 

The cannibalized Cougar electronics will be connected with my old F22Pro/TQS and will still do a good job for use with my W9X/XP retro flight sim collection .

 

What I'm really interested in is, has someone already made some other grip handles for the Warthog throttle? I know some projects for the stick, like DIY spitfire, KG12, P-51 and even B8 grips, but I've never seen anyone making other throttle grips. I also considered to buy a WinWing Throttle for the F/A-18 but there ist the CE problem if you live in Europe and second you have to use the SimAppPro to program this device.

 

I wanted to use one configuration software for all my devices. Atleast for the ones that are interchangeable. The yoke and the multiengine quadrant are mostly used together so there is no need to be compatible with the rest, the only other thing that want be TARGET compatible will be my collective. Maybe I will also find a solution for this.

Edited January 30, 2021 by Viper1970

[Sokol1_br]

Up to now the only grip modification showed for Warthog throttle was an Cougar TQS grip adaptation, if I remember correct in the Russian side of this forum.

 

For use B-8 (FCS, PFCS, X-Fighter) and Suncom "F-15'ish" grips - or an 3D printed grip in Warthog base, check Debolestis topics, an well detailed "how to" with  the list of needed parts. 

 

Use TWCS circuit for Cougar TQS is an viable idea, this controller has the necessary 5 axis input - in fact have more 3 that can be used for connect rudder pedals (or a trim wheels); and more buttons than TQS had. 

[Viper1970]

Hi sokol, thanks for your answer. I'm always fascinated by the knowledge you have in this genre. I often read your comments here and also at Sim HQ, to learn for my own projects.

 

I've seen Depolestis topics and also asked if it's possible to use the old FLCS/F22Pro grip PCB's with the Warthog/Cougar electronics. I have seen a video on youtube from guy who had made this but he doesn't explained it in detail. He only told that not all of the buttons and hats are 1:1 like they are with the original grip PCB fom the Warthog or Cougar, but principal they are still useable. I know there exist new projects for grip PCB's you can do by yourself but I still have many of the old FLCS PCB's useless lying arround.

 

P.S:

To use the TWCS for a Cougar throttle stand alone was an idea that came to my mind, to still be able to use it with TARGET. I hope it is really doable. If it's possible I will report it here.

Edited January 30, 2021 by Viper1970

[Sokol1_br]

Use Warthog grip CD4021 Shift Register PCB in other grip is an expensive alternative.

 

CD4021 Shift register is cheap, Debolestis used to sell then for 8, 16, 24 buttons, check this topic.

 

 

[Viper1970]

Hi Sokol,

 

yes I know, but I also wanted to have the new hat mechanics for my B8, F-15E, AH-64D and OH-58D sticks (the most important I want to have). For other further projects in the future, I also wanted to be able to use the grip PCB's from my old FLCS/F-22Pro. I have nearly 20 of them useless lying arround here. Is there any wiring diagram for the old grip PCB's of the FLCS (from 1992-95) to use them with the Warthog base?

 

I have also made 3D models of the grip handles from the F/A-18C and the F-14D (a bit more advanced as the one of the F-14B) which I wanted to print with my 3D printer an make them compatible with the Warthog throttle grips. Most of the original buttons and hats could be reused, you only have to print some F/A-18 and F-14 coolie hats and connect them to the original hat mechanics. For the F/A-18 throttle the only problem is the second push button on the left handle, that is missing on the warthog. I will use one of the push buttons from the base here and make the wiring to the grip. For the antenna elevation I'm going to use the friction lever from the base. It's not original in case of handling, but with the use of TARGET there should be a way of making it functional like it is in the original Hornet. May be there is also a way to make it spring loaded.

 

The third throttle I want to build is the one of the F-15. There isn't so much difference to the A-10 throttle. Only the POV on the right outside has to be removed and replaced with a fourth three position switch and some other minor corrections. The F-15 style switches I will use from my old Suncom F-15 throttle or maybe print some new with my SLA printer. For the antenna elevation on the left handle I will do the same thing as with the F/A-18 throttle.

 

P.S: Sometimes you have to convert a hat to a three position switch, but thats no problem as you can work with PRESS/RELEASE functions for the middle position and just leave the UP/DOWN from the hat unused.

 

Here are some of the 3D models I made. The throttles were meant to be used with my old Suncom SFS throttle bases (the reason why they have conncections for simple AB-detend mechanics I made with the use of a lock bar and also a connection for the original SFS throttle lock). Now I have to rebuild them an use only the grips for the new Warthog throttle bases I just bought. The AH-64D cyclic must also to be adjusted. All models could be separated to 3 or 4 parts to connect the wiring and the electronics. I also made a V-22A Osprey throttle and a universal useable collective. For the OH-58D I will use a bought STL-file from an EC-135 which is identical to the OH-58D cyclic.

Edited January 31, 2021 by Viper1970