replacing buttons with hats on Suncom Stick

[leafer]

I want to replace the buttons on the stick with cougar hat switches, but need advice on how to drill perfect circles into the plastic. I went to a local hardware store and was advised not to do this because the grip will crack. But I don't believe him. My other problem is how I'm going to enlarge the hole for the thumb switch. I can't figure how I'm going to drill a straight hole when the top switch housing is in the way.

 

Some advice would be greatly appreciated.

 

27/11/11 update:

 

Anyone know how to distinguish the power from the ground pins on the hat?

Edited November 27, 2011 by leafer

[Deadman]

Hi Leafer finally getting some mods done on the stick here is a link to a thread over on the X-plane form showing some modes done there may be others at Sim HQ on the same subject Good luck:thumbup:

http://forums.x-plane.org/index.php?showtopic=27496&hl=suncom&st=20

[leafer]

Well, I cracked it a little. FROG!

[Sokol1_br]

Leafer,

 

 

I change a four way (castle) hat, with + shaped hole to 8 way HAT in

Suncom Talon sitck.

 

To open hole, dont use electrical tools, like Dremel - probable end in stick damage - unless you have skill with then.

 

Use a model knife, like these

 

http://www.brasilhobbies.com.br/ecommerce_site/arquivos4477/arquivos/12864957931.jpg

 

Cut careful, in small steeps, ad finish manual with circular stick wrapped with sandpaper.

 

Sokol1

[Jimbo]

Hi Leafer, I have a couple of Suncom sticks (Talon and Raptor) in my loft.

 

I was planning on modding them many, many years ago but now the hog has superceded the throttle and theyr'e just gathering dust... If you need spares PM me and I'll see if I can dig them out.

[leafer]

I tried an x-acto knife but it can't cut through the plastic. My Suncom Raptor thumb switch housing has 2-3 mm hole that I need to enlarge to fit a much bigger hat switch. I'm thinking of doing that with a really hot drill bit first then file to size.

 

Jimbo, thanks, if I mess up anymore I'll definitely need another. :)

[LtFransky]

Actually, don't use a drill bit with the dremel. Use a milling bit. Like this:

 

http://www.dremel.com/en-us/Accessories/Pages/ProductDetail.aspx?pid=194

 

It will shave the hole until you're close to the desired size. Then use this:

 

http://www.dremel.com/en-us/Accessories/Pages/ProductDetail.aspx?pid=407

 

to make the hole nice and round. It's not hard to do, but you have to take your time and GO EASY. Drill bits put too much pressure in the centre of the hole, and they only grab in 2 spots. That's why they crack the plastic.

 

A scriber would work better than an X-acto because it actually removes a thin ribbon of plastic rather than pushing it out of the way.

 

http://www.cyber-hobby.com/shop/index.php?main_page=product_info&products_id=7915

 

Do the thumb switch in 2 halves.

[PeterP]

Don't forget:

always try it first on a similar sample of plastic before you do it on the part of the HOTAS. - So you already know how the tool/plastic will react and you know what rpm you have to use that it doesn't get to hot and melt.

[leafer]

I don't have a dremel, that thing costs the same as a decent Saitek Hotas in Thailand. The drill I used was an air drill at a local garage which was too darn powerful. I'll post some pics when there's progress.

 

And thanks for all the good advice. :thumbup:

 

UPDATE:

 

DON'T USE A HOT DRILL BIT TO OPEN HOLE IN PLASTIC. lol Luckily, I tried it on unused throttle base first. Thanks, PeterP!

 

What ended up working, though no where near perfect, were those little grinding stone bits. I managed to open a hole for the middle hat switch but it is off center. My non robotic hand just couldn't keep the massive drill steady enough, and my wife didn't want to play like a vise grip. I opened half the hole for the thumb hat, but it looked terrible. So for the other half, I will cut out the general shape with a saw first then grind to shape.

 

Will post pics tomorrow.

Edited November 26, 2011 by leafer