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Showroom 2DOF First Platform Build + Custom Peripherals

Discussion in 'DIY Motion Simulator Projects' started by Megadeth, Aug 8, 2016.

  1. Megadeth

    Megadeth New Member Gold Contributor

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    This project started out as just a frame for a chair and pedals. I decided to build one myself as I never really had any fabrication skills and wanted to learn how to weld. Also I had already picked up a chair for $50 and my mate could get scrap steel from his work for free. Materials used were 25x25mm square tube in stainless steel. So lets begin from the start.

    20150627_174951.jpg

    My cheapo chair I picked up. I didn't get many build pics of the start of the frame. This is the basic design that will sit on the floor.

    20150627_175009.jpg
    The steering wheel at the time was the trusty old g27 which will clamp to that top bar. The H pattern shifter will clamp to the little piece of square tube sticking out the side.

    20150627_175016.jpg

    20150629_175832.jpg

    My mate helping me out with the trickier welding as I just seemed to heat up the steel with the TIG welder.

    20150629_204007.jpg

    Here I give you MK1 of my frame.

    20150630_172754.jpg

    Comes with a custom brick setup to hold the pedals in place lol! Can I sense a hydraulic pedal build?

    20151106_211822.jpg

    Yep you guessed it some Wilwood custom hydraulic pedals. I decided on using stainless steel 3/16 tubing with -3AN flare nuts. Was a pain in the ass to flare. Had to heat it up to stop it from cracking. If you want to go down the hard line route I suggest using normal bundy tube, so much easier to work with but to keep in theme with my frame stainless steel was chosen.

    20151106_211940.jpg

    I used 80/20 in 30mm tube to build the frame for the pedals to mount to. Here you see the master cylinders hooked up to the pull slave cylinders.

    20151106_211956.jpg

    Sorry for the poor pic. The electronics are going to be housed at the front in a junction box. All my wiring will be kept within the pedal set so its modular. All that is needed for these to work is a USB cable.

    20151110_222855.jpg

    A piece of checker plate aluminum got bent up to go over the electronics and to bring your feet up to the pedals.

    20151110_222925.jpg

    Can see where all the wiring leads back to. I'm using a hall sensor for the throttle attached to the piece of stainless steel coming up of the throttle pedal bolt. The magnet on the throttle pedal moves past the hall sensor which sends a signal to the DSD pedal board resulting in acceleration without using pots or pressing on loadcells.

    20160225_200446.jpg

    Had to figure out a way to mount the pedals. My solution was simple, cut 2x 25mm tubes and drill holes in the centre for m8 35mm bolts. Using 80/20 m8 sliding nuts I could slide my pedals in between the tubes and do up the bolts making it a solid fit.

    20160226_183937.jpg

    Received some goodies from Ascher Racing. I must say these carbon fibre paddles are the best I've used, well worth the money.

    20160228_145402.jpg

    In the process of building all this cool stuff I couldn't resist building a MMO's force feedback steering wheel as well. It compliments the pedals so much better than a g27. Here it is with a rip off Sparco wheel and those awesome carbon fibre paddles.

    20160602_172009.jpg

    I also made a button plate out of some carbon fibre. I bought a second hand H pattern shifer off an arcade machine as well. The button plate and shifter are both wired into a Teensey with programing done by a mate.

    20160715_210423.jpg
    No rigs complete without a handbrake. Whipped up this beauty one Friday night. Just an ebay cheap chinese drift brake. Plumbed it up to a slave pull cylinder with a pressure transducer like my hydraulic pedals. This is wired into my DSD board in my pedal box.

    Enough porn now lets get on with this 2DOF build

    20160716_143149.jpg

    First things first because my pedals sit on the ground I'm going to have to offset them so they sit 150mm lower to make it more comfortable. Being on the ground the pedals were a bit high making an uncomfortable postion for long races. Also I don't want to bash my knees on the steering wheel frame when this thing starts rocking!

    20160716_154832.jpg

    Drop legs made and tacked now time to brace them.

    20160716_180039.jpg

    Bracing done on the pedal drop legs. Used 50mm x 6mm flat bar for the outside bracing.

    20160717_111840.jpg

    50mm x 6mm flat bar was also used on the bottom of the frame for where the uni joint will bolt to.

    20160717_170750.jpg

    Using 200W motors from motion dynamics with 25:1 gearbox. Made the mounts with 50mm x 4mm angle held together with m6 bolts.

    20160717_170837.jpg

    Made up the bottom frame. Using just some scrap 10mm mild steel plate to weld the uni joint to.

    20160717_191131.jpg

    Tacking the base for where the motors are going to mount.

    20160725_151035.jpg

    Welded up some lever arms. They are 50mm CTC. I made it from 1/2" rod which got welded to the 50mm x 6mm flat bar. I then threaded it to 1/2" UNF to accept nuts to hold the rod ends in place. On the pot side I drilled a 6mm hole and welded a 6mm bolt in and chopped the head off. A flexible coupling will join 6mm thread to the pot.

    20160724_161206.jpg

    Motors and uni joint now tacked into place, now to make up some arms.

    20160725_112442.jpg

    The arms were made by cutting 25mm square tube into 4x 25mm pieces. These 4 pieces had a 12.5mm hole drilled in the centre and 1/2" rod inserted and welded in. I then threaded them to 1/2" UNF to accept the rod ends. I then welded these to some 25mm square tubes.

    20160724_171015.jpg

    Finally getting somewhere. Everythings looking good.

    20160728_193452.jpg

    Did a mock up and top frame was a bit bendy so additional bracing got added to make it more metal!

    20160725_211321.jpg

    Inside finally. Welded in some bar and angle for the PSU's to sit. Still have to make up some guards so people don't kick the pots. Next one I build I'll put the pots on the inside.

    Finally here it is complete

    20160808_114015.jpg
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    Haven't figured out what to do with the electronics yet. Might 3d print something to house them in.

    20160808_114052.jpg
    20160808_114108.jpg
    20160808_114138.jpg

    Any questions feel free to ask
    • Like Like x 2
  2. Slider

    Slider Active Member

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    My Motion Simulator:
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    Not bad for just a frame and pedal housing! Good stuff.
  3. Megadeth

    Megadeth New Member Gold Contributor

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    Thanks mate was going on a limited budget build so I could spend more on the peripherals. It is definetly worth it and so much more satisfying when you build it all yourself.
  4. noorbeast

    noorbeast VR Tassie Devil Staff Member Moderator Race Director

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    My Motion Simulator:
    3DOF, DC motor, JRK
    Can you please insert the pictures as thumbnails, as for anyone like me on a slow net connection the page will not load correctly.
    • Informative Informative x 1
  5. Megadeth

    Megadeth New Member Gold Contributor

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    For those who can't see the images here they are in thumbnails


    20150627_174951.jpg 20150627_174951.jpg 20150627_175009.jpg 20150627_175016.jpg 20150629_175832.jpg 20150629_204007.jpg 20150630_172754.jpg 20151106_211822.jpg 20151106_211940.jpg 20151106_211956.jpg 20151110_222855.jpg 20151110_222925.jpg 20160225_200446.jpg 20160226_183937.jpg 20160228_145402.jpg 20160602_172009.jpg 20160715_210423.jpg 20160716_143149.jpg 20160716_154832.jpg 20160716_180039.jpg 20160717_111840.jpg 20160717_170750.jpg 20160717_170837.jpg 20160717_191131.jpg 20160724_161206.jpg 20160724_171015.jpg 20160725_112442.jpg 20160725_151035.jpg 20160725_211321.jpg 20160728_193452.jpg 20160808_114015.jpg 20160808_114032.jpg 20160808_114052.jpg 20160808_114108.jpg 20160808_114138.jpg

    Attached Files:

    • Like Like x 3
  6. EntonoX

    EntonoX Member

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    o my, seems like its not the first time you did something like this :eek:
    Really like the pedals and steering wheel! Good progress, looking forward to see the thing in motion.

    Any estimates for the total costs for this build?
  7. Megadeth

    Megadeth New Member Gold Contributor

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    Haha it is the first time I've built all these things. Wiring to me is second nature being in industrial refrigeration it's sort of my job. Nothing is complicated with the right wiring diagram.

    I did a rough estimate for the whole build is $3750 to do it yourself. You can save money by making your own pedals, that will save you $400. Not spend $300 on a sparco wheel lol buy a cheaper one. Also using mild steel will be quite a saving over stainless steel.

    If you already had a rig and you wanted to convert to motion I reckon I could do it for $500. All prices in Aussie $.
  8. Megadeth

    Megadeth New Member Gold Contributor

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    Here's a quick video of the simulator in action. My mate was playing, after he got off he asked how much lol

    • Like Like x 1
  9. stomper

    stomper Member

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    My Motion Simulator:
    2DOF, DC motor, Arduino, Motion platform
    Nice build. You have done a top job.
  10. Megadeth

    Megadeth New Member Gold Contributor

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    Thanks mate will try and do a better video over the weekend. All it needs now is vr
    • Like Like x 2