NLR Boeing flight chair G-Seat

Im repurposed a NLR Boeing flight chair that I found on Marketplace for $250 second hand into a motion G-seat. I hope to be able to post some pics of it in motion in the next couple of months.

I bought the seat on November 15 of last year for $250 on Marketplace, and promply began taking it apart. Then I started drawing it up, which took a couple of months.

In the mean time I found a DOF Reality control box for $100 with the center channel not working. I didn't care becaue I was getting rid of the IBT-2 motor drivers and Uno board. I really wanted it for the encosure and 4 350w power supplies.

After having a DR 3DOF for a short period of time and modifying it, trying to make it more realistic, I realized simple motion wasn't for me, and just adding more motion made it less realistic. I didn't just want a motion chair; I wanted a moving G-seat. There have been some atempts here and there to make them, but everyone is going after big motion and unrealistic flap motion. I spent a lot of time watching vids of military motion seats. There don't move much but the seat flap, back flap, and harness ratios are very specific. The primarly use airbags to simulate g-forces. That is not a reasonable approch for a home sim. So I'm using cables and levers to actuate the flaps and harness. So I started hacking the seat apart and reassembling it into something different.

I spend today finishing the control box. I replaced the IBT-s boards the MD30C's. The Mega2560 was swapped out for a Nano EPS32. I also changed out the front panel connectors to handle the 5500 RPM/475w motors I'm using (more on that later). I also swapped out the 3-pin din connectors for CAT6 as I'm using AS5048A magnetic sensors. This is a closed loop position control system so I need the extra wires. Here's some pics of the finished box.
I also finished assembling one of the motors today. I hope to finish the other two tomorrow. Then it will be time to put some power to it and start bringing it up to speed.

There were 2 80mm fans inside, above the motor drivers. The new boards are much bigger so the fans won't fit inside. I'll be printing a housing to mount them in the same location but on top of the box. That, and the beauty ring around the USB-c plug are (hopefully) all I have left to do for the control box.

These motors came from a couple of wheelchairs I got from a friend after his aunt passed. They are pretty beefy. They use american measurements so I had to elengate the mounting holes so it would mate the the 50:1 planetary gears. I also had to cut an interface ring on my Snapmaker. I had to have the drive shafts made. The guy did a great job as there in 0 play in them. I also cut the sensor and limit switch mount. The switch works for both directions. All three motors are built. Next step is to wire up the control and power wires to the motors. Hopefully this week.

Got the motors mounted to the frame this evening. I may be able to finish wiring them up tomorrow. Then it will be time to test and tune them before remounting the seat.