Community Event / Creation DIY Controller and Throttle

I've received the PCB's and switches this afternoon, bang on time for the jobs ahead. Today I finished putting on all the nuts and bolts for the housing. This basically mean that I should be able to cut the MDF for the columns tomorrow and all will be ready for assembly on the sunday. It won't be the definitive assembly because due to some stupid calculation i will be unable to mount the lighting for the panels. Fortunately everything can be taken apart so no big deal.

Well alright here's some pictures then.

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Holy shiznit Cataclysm, have you considered applying for a job with a Formula 1 team!?!? Your fabricating skills are stellar!

Youire kickin some serious butt, keep at it!
 
Diner table turned Workbench

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Applying glue to the panels/ The acryl glue i used to glue panel-to-panel works particularly well on the leather. Apply the glue with a cotton bud on the plastic, wait 15 seconds for it to get sticky, and then pull/press the leather into shape. Add weight or clamps to settle. It sets in 20 minutes, perhaps less.

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Results!

I did the leather on the throttle stick a few weeks back, I just put it in for reference.

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Here are the two console panels side by side. The lads with a keen eye already noticed the small switch panels semi-assembled.

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Today I did some wiring on the switch banks, and I assembled the two logic boards. To save costs on making the pcb's, they are actually the same PCB for both throttle and stick. With a few solder jumpers they can be configured as master or slave board:

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Also, i've worked on mounting the control consoles to the mounting columns (the vertical bits next to the seat). It took some thinking to get it like it wanted. For example, I needed a way to access the wiring without having to disassembled the entire console.
 
Today I did some wiring on the switch banks, and I assembled the two logic boards. To save costs on making the pcb's, they are actually the same PCB for both throttle and stick. With a few solder jumpers they can be configured as master or slave board:

View attachment 68087

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Also, i've worked on mounting the control consoles to the mounting columns (the vertical bits next to the seat). It took some thinking to get it like it wanted. For example, I needed a way to access the wiring without having to disassembled the entire console.

Ok that is just awesome!

If it's ok, I do have some questions.
1. The pcb's receive the input from the switches, then send the inputs to the arduino for processing, then the arduino sends those inputs to the computer, is that correct?
2. The large black rectangle on the right side of your pcb's looks like it can have a chip installed into it, what type of chip would go there and what would it do?
3. What does the red switch box on the pcb's do?
4. Why is there a need for a reset button on the pcb's?
5. What software will you use to program the arduino/buttons?
6. Could you post a picture of the back of the pcb's?

Sorry for all the questions but as I've mentioned before, I'm interested in learning to do DIY button boxes myself, so I've taken a very keen interest in your build.

You rock! Very excited to see this completed but at the same time I don't want it to end!
 
Ok that is just awesome!

If it's ok, I do have some questions.
1. The pcb's receive the input from the switches, then send the inputs to the arduino for processing, then the arduino sends those inputs to the computer, is that correct?
2. The large black rectangle on the right side of your pcb's looks like it can have a chip installed into it, what type of chip would go there and what would it do?
3. What does the red switch box on the pcb's do?
4. Why is there a need for a reset button on the pcb's?
5. What software will you use to program the arduino/buttons?
6. Could you post a picture of the back of the pcb's?

Sorry for all the questions but as I've mentioned before, I'm interested in learning to do DIY button boxes myself, so I've taken a very keen interest in your build.

You rock! Very excited to see this completed but at the same time I don't want it to end!
No worries about the questions! I will gladly answer them. If i wasn't fishing for compliments or talks i shouldn't posted it in the first place, lol.

Here we go:
1. Correct
2. That socket is for the MCP23017 IO Expander. It receives the input from the analog switches, converts them to a serial signal which is sent to the Arduino. The MCP23017 can be configured with a unique ID (the red switches) so i can daisy-chain the expansion boards. The Arduino doesn't have enough pins to cope with all the switches and by using these IC's I can expand them to up to 128 signals, or (8 boards) without having to redesign my entire PCB's.
3. See #2, it configured the slave address
4. The Arduino doesn't have a reset switch on the board, and press a button is easier than unplugging/replugging the joystick. Only the Master board needs the reset switch. On the photo both boards have a reset switch, but that is my error.
5. No software. The buttons are simply mapped to the USB HID descriptor. The only exception are the HAT1 and HAT2 connectors on the Master board, they are mapped to a HID 5-way hat for easy configuration. I should say that my firmware does some internal tricks to push lighting effects (which is handled by a separate board).
6. The back side is the least interesting bit. You only see the soldered connectors. There's no parts, and the few traces there are covered by a while silkscreen. So basically, it is a blank.

My current setup still uses the prototype boards you saw in previous photos. The IO expanders that I have are soldered to the boards and I am all out of MCP23017's. This is why the sockets on this picture are empty. I am waiting for a new set of chips to come in.

The white boards are really nothing special. The most important thing they do it split up the many GND and 5V lines and provide a good connection between all the pins. I am almost a religious person when it comes to polarized connectors. Every connector was configured for a purpose and brings its own GND or 5V lines. This way i have no wire splices in the rest of the project and this allows me to build the thing one segment at a time.

Here's a low resolution diagram of the PCB. It proves the simplicity of the board. This ain't rocket science, the heavy work went in the firmware (analog input smoothing) and the hardware design.

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Hey Cat... I have read through your posts in this thread and been inspired. I need to start on something for myself. Being a "leftie" means that an off-the-shelf HOTAS isn't an option. I stumbled upon this thread and now have visions of my entire garage being decked out like the interior of a Mk III Cobra. Thankfully my Wife would never let that happen. I signed up to this forum just so that I could say that you are doing an awe-inspiring job despite everything and I can't wait to see the finished project. Keep rocking!

Richard
 
Hey Richard,

My project was made possible because I have built up a little knowledge of electronics, I have a degree in computer engineering, I have a 3D-printer at home, and access to a laser cutter at the local MakerSpace. Without any of these 4, it would have been a disaster.

Thankfully my Wife would never let that happen.

Also, I do not have to consider a WAF (Wife Acceptance Factor) because I am a grown man living on my own (that isn't as scary as it sounds).
 
(Apologies for the bad picture, my camera battery was dead)

Progress has been made. Except for the backlight, the armrests are finished. The switches have their lights. Also i've found some time to cut the boards for the armrest columns as you see in the photograph. This is just the bare MDF without screws. I'll be countersinking all the screws, then disassemble everything for priming and painting later this week (possibly tomorrow).

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I have some spare panels of MDF that I want to use to hide the wood beams near the seat bottom. A simple painted triangle would be enough for that, and it doesn't need to be any kind of fancy.

When these have been done, I can move my attention towards the triple display setup with the next set of switches!

AND SO, THE END IS NEAR
 
I know im repeating myself but your work is looking very professional Cat!
The hotas looks store bought and has a very nice retrolook which suits ED amazingly well!
 
first coat of primer on!

The primer is drying while I am sawing the next panel in a different room. Now is that efficient time management or not?
 
I am radiating envy, can you feel it? CAN YOU????
WIsh I had the room for a dedicated 'pit but I'd need one for E: D, one for DCS A10-C, One for DCS KA50 one for ........

:D

Lovely Job, well done!
 
There is still a huge list of work to be done:

- add backlighting to the console panels
- finish paneling behind seat to hide structure beams
- design/build triple display mount
- design/build front console paneling
- connect front console lighting effects
- build a PC to drive triple display
- take some nice pictures
- write a long and short version of an article about this project.
- etc..

But these jobs will have to wait for a while; i need to get find some funding for the next phases. And perhaps enjoy a little gametime.
 
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Another benefit of developing your own dashboard:


While playing, i started to get annoyed by the fact that the game does not support a press mode for stuff like the landing gear. It is only usable as a press-once button. As it does not have a 'hold' state my panel of switches doesn't work. When i want to deploy the landing gear I have to flip the switch once for 'press' and flip it again to 'release' the key.


So instead I added some programming to the firmware of my joystick. Designated switches will now act a button presses when flipping it up will push a key for 200msecs and release it automatically. Then, when switching the toggle to 'off' it will emit another buttonpress for 200msecs; it turns out it works really nice, and because I am running a lighting animation when the switch is up (or on) i get nice visual feedback on the state of the landing gear. All I need to take care of is that the switch is ON when I start the game and launch from a docking station.


No pictures. This is software only :(
 
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Crafty solution, like that a lot :)

I think i did request this (hold funtion) way back in beta but no harm in submitting another request in the appropriate forum.

Nicely done!
 
Just a quick assembly of the triple display setup. The middle one still needs alignment; they are actually 3 of the same display but somehow the middle looks smaller. This setup allows me to see how it is all going to look once I figure out the wood beam structure.

Suddenly the setup went from small to massive.... #noWayBackNow

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Wow, just found this thread, amazing work! I don't think I could pull off all the custom electronics, I would be hopelessly lost. Definitely going to be keeping a close eye on your updates! :D
 
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