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80/20 Aluminum profile 2DoF build.

Discussion in 'DIY Motion Simulator Projects' started by Watchumacallit, Dec 12, 2018.

  1. Watchumacallit

    Watchumacallit Member

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    Starting my first DIY motion sim build. Hope I don't screw anything up too badly. I want to Thank @noorbeast for answering my noob questions and @Kranky Pantz for sharing his parts list and also answering my questions.

    Originally I wanted to build a motion platform like @Erwan960 as I have a similar rig as his but I was afraid my OSW and pedals where going to be too heavy. So decided to go with a seat mover instead.
    IMG_2161.jpg IMG_2163.jpg

    Ordered my motors and U joint(Yea, it was painted green by seller for some odd reason) from PGSaw ebay store and some more aluminum profiles. Drilled holes on mounting plates to accommodate profiles.
    IMG_2164.jpg

    Had to dis assemble one of the gearbox to turn shaft around.
    IMG_2165.jpg

    Dis assembly of the rig and mock up. Got L brackets for motor mounts from local hardware store.
    IMG_2166.jpg IMG_2167.jpg

    Will soon drill holes on brackets and attach motors and chair to frame.

    Completed Build!
    IMG_2257.jpg IMG_2256.jpg IMG_2252.jpg IMG_2253.jpg
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    Last edited: Dec 28, 2018
  2. Kranky Pantz

    Kranky Pantz Active Member

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    My Motion Simulator:
    2DOF, DC motor, JRK, Motion platform
    Woohoooooo!!!!!!

    And so it begins......

    Congrats, and I hope that everything moves along smoothly for you.


    Am I seeing that right, are you using a TM Alcantara 599xx Evo rim on your OSW wheelbase???

    Did you make a custom mounting ring or something, and also...do the buttons work????

    Pretty slick!!!

    PS No thanks needed, it's been a pleasure conversing with you, and don't forget that I'm just as much of a newb at this as you are...only with a 3 month head-start.

    I'm looking forward to watching this build come together. :popcorn

    Cheers!!! :cheers
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    Last edited: Dec 18, 2018
  3. Watchumacallit

    Watchumacallit Member

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    Hey Kranky,
    How is everything? Got the rig tuned in?

    Yea, that is a TM wheel on my OSW. I got it from Ricmotech. It was on sale at the time and was too good to pass up. The buttons do work and it is OK for the price. I say that because there is a little flex on the wheel. Not noticeable though when racing but when i crank up the power on the OSW it can't handle it. Might invest on a better wheel after the build.

    and hey, thanks again for your help!
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    Last edited: Dec 12, 2018
  4. Kranky Pantz

    Kranky Pantz Active Member

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    My Motion Simulator:
    2DOF, DC motor, JRK, Motion platform
    Everything is going well, thanks.

    Yes, the rig is performing as I had hoped, and the tuning is going great.

    I just keep hammering away at testing a new plugin once I get the previous one functional.

    The Crew 2 just went free to play on Steam from now until the the end of the weekend, so I'm downloading it now and will be testing out that new Destruction Derby mode.
    It should be fun, and since the Wreckfest plugin no longer works now I'll be able to get my arcade-type of racing fix when the urge strikes.
    If it all goes well then I'll buy it because it's also on for 67% off...so there's no risk due to the free trial period, win-win!!!

    I use that same exact 599xx rim on my setup, really like it for what it is.

    Someday I'll upgrade, but it does the job for now and is probably the best TM rim in their lineup, aside from the F1 which is a nice contrast to also have on hand.

    Your build is looking fantastic so far, and it looks like you're off to a great start.

    Cheers!
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  5. Watchumacallit

    Watchumacallit Member

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    Seat and motors mounted.

    Was going to put motors under seat but not enough height. Didn't want to go too high as my wheel deck and pedals will end up being too low.
    IMG_2172.jpg

    Turned motor around and will face levers backward toward the motors.
    IMG_2173.jpg IMG_2174.jpg IMG_2175.jpg IMG_2176.jpg
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  6. Kranky Pantz

    Kranky Pantz Active Member

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    My Motion Simulator:
    2DOF, DC motor, JRK, Motion platform
    Lookin' gooood my man!!!!!

    I'm glad that your order from PG Saw made it out prior to the effects of our postal strike here in BC, it's really bad now.

    That's the beauty of having all of the parts on hand, you can make changes to their orientation as you see what works best.

    Do you have your electronics box sorted out, along with the power supply(s)?

    Heeeeyyyyy, those dual motor L-brackets look awfully familiar, LOL!!!
    I can vouch for how solid that system is, and if you can also add a rod between the spare holes on the top of the motor gear casings it'll be even sturdier.
    Mine also doubles as the hanger for the feedback pots, so it serves a dual purpose.

    Please keep those pics comin'!!!! :popcorn
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    Last edited: Dec 14, 2018
  7. Watchumacallit

    Watchumacallit Member

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    I haven't had a chance to get the controller box and power supply sorted yet. I do have all the parts on hand. Just trying to finish up the levers and rods to gear box.

    Yea, those brackets are sturdy.:thumbs
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  8. Watchumacallit

    Watchumacallit Member

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    Today I was able to put levers and push rods together. its looking more like a motion rig now!:grin
    Will weld levers to 12 mm rods when everything starts to move so I can still make adjustment if i need too.
    IMG_2178.jpg IMG_2179.jpg IMG_2180.jpg IMG_2181.jpg IMG_2182.jpg
    56658552126__9E0D2331-60BF-4545-8635-7726103983D7.JPG 56658556111__C7E5F9B9-AADA-4CBB-B21F-88F7E72AF676.JPG

    Next up Control box. Got this pelican case that will fit JRK's and fits perfectly under the seat.
    IMG_2202.jpg IMG_2201.jpg
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  9. Watchumacallit

    Watchumacallit Member

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    Bwoah, didn’t get much done this weekend as this thing called “family time” got in the way, smh!;)

    Drilled through rod and tapped with m4 screw to prevent it from spinning independently.
    upload_2018-12-16_15-41-7.jpeg upload_2018-12-16_15-40-26.jpeg upload_2018-12-16_15-39-29.jpeg

    Finalized gearbox and levers.
    upload_2018-12-16_15-37-4.jpeg

    Will probably be able to do control box and the electronics in the coming few days.

    Hope I can qualify for a DIY license.
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  10. Kranky Pantz

    Kranky Pantz Active Member

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    My Motion Simulator:
    2DOF, DC motor, JRK, Motion platform
    You are killin' it!!!!!

    "Hope I can qualify for a DIY license."

    Are you kidding me?????

    At this rate you are most likely qualifying for a MEDAL!!!!

    :cheers
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  11. Watchumacallit

    Watchumacallit Member

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    Thanks Kranky!

    Getting the electronics ready. Will request license when everything is hooked up.

    Can’t wait for this thing to move! I get in the rush mode mentality and have to stop and tell my self to slow down a bit as I end up messing things up.:(
    So far so good though!
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  12. Kranky Pantz

    Kranky Pantz Active Member

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    My Motion Simulator:
    2DOF, DC motor, JRK, Motion platform
    Live For Speed is perfectly usable with the demo version of SimTools.

    Once I had that functioning properly I requested a DIY license in order to progress and get into the real nitty-gritty of testing.

    My DIY license was granted within 24hrs, or more like 12hrs if I remember correctly.

    I still plan on upgrading to the Pro license sometime in the future, once I'm more comfortable with refining my profiles and wish to move on to the more advanced features such as Game Dash & Remote Profiling.
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  13. Watchumacallit

    Watchumacallit Member

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    Was able to get JRK’s hooked up to power and it didn’t blow up so I’ll take that as a win. Didn’t have a chance to do JRK utility yet as it was getting late. Once I get the fan and access holes done then I’ll hook it up to PC and see what happens.
    upload_2018-12-19_0-38-47.jpeg
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  14. Watchumacallit

    Watchumacallit Member

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    Today I was able to finish the electronics. It came out pretty good. Nice and compact.
    upload_2018-12-20_19-32-13.jpeg upload_2018-12-20_19-33-3.jpeg upload_2018-12-20_19-33-54.jpeg

    It’s Alive!!!
    Was also able to do a test. Wow this thing is awesome. To compare, It’s like going from a cheap steering wheel to a direct drive wheel. I only had bass shakers before and this thing is on another level. It’s louder than it is in real life as I was pointing my phone directly at the rig.


    I am experiencing a little problem though. One of the two PSU keeps cutting off and tripping. Sometimes it’s the left and sometimes it’s the right. I don’t have cheap knock off power supplies either. I have meanwell units so I doubt it’s that. Maybe it’s one of the setting in the JRK utility.

    On the end of this video the left PSU tripped.


    If anybody have any idea why the PSU is tripping, please let me know. Thanks!
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    Last edited: Dec 29, 2018
  15. noorbeast

    noorbeast VR - The Next Generation Staff Member Moderator SimTools 2.0 Beta Tester

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    My Motion Simulator:
    3DOF, DC motor, JRK
    A few suggestions.

    With a lever range anything over 40 degrees up and down is really inefficient in terms of torque utilisation, and yours look like they are well over that.

    How well is the rig balanced,with you in it, as it is a bit hard to judge from the camera angle.

    What is the CTC distance on the levers, because on a compact design torque matters more than lever linear speed.

    Are you using clip on ferrite magnets on usb cables, as that and good cable management will help mitigate interference.

    Can you please post pictures of all of your JRK settings.
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  16. Watchumacallit

    Watchumacallit Member

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    Hey Noorbeast,

    Yes, levers does go over 40 degrees up and down. It’s set to 45 degrees right now. I’ll lower that to 40 degrees.

    It’s well balanced as I sat on it before I installed the motors and levers and was able to keep my self up for a while with out tipping over.

    CTC distance is 50mm

    Ferrite magnets check. Have it on all my usb cables as OSW also produces a lot of EMI.

    Here is my JRK G2 utility settings
    upload_2018-12-21_7-47-10.jpeg

    upload_2018-12-21_7-48-38.jpeg

    upload_2018-12-21_7-49-40.jpeg

    upload_2018-12-21_7-50-15.jpeg

    upload_2018-12-21_7-50-41.jpeg

    Thanks for your help!

    Attached Files:

  17. Watchumacallit

    Watchumacallit Member

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    Was able to fix my issue and now it’s awesome!!!

    Called Pololu support and suggested to add shunt regulator between PSU and JRK G2’s.
    Installed shunts and no more PSU cut offs.
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    Last edited: Dec 22, 2018
  18. Watchumacallit

    Watchumacallit Member

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    Hey Noorbeast,
    Now that that problem is resolved. Is it a good idea to have a little angle on the lever rods. I have my set to 10 degrees forward right now. Is it a good idea to leave it that way or should I make it straight when it’s leveled?
  19. noorbeast

    noorbeast VR - The Next Generation Staff Member Moderator SimTools 2.0 Beta Tester

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    My Motion Simulator:
    3DOF, DC motor, JRK
    Torque utilisation is most effective at 90 degrees, so it really is a question of how your rods are set up, whether they are perpendicular or angled. But either way 10 degrees is less of an issue that having a range that is well over 40 degrees up and down,as effective torque utilisation drops of pretty dramatically after about 38 degrees.
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  20. Watchumacallit

    Watchumacallit Member

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    Ok, thanks! I did drop it from 45 degrees to 40 degrees. I also lessened rod angle from 10 degrees to 5 degrees. You are right though as I can’t really tell the difference between 5 and 10 but I did notice a better response from 45 to 40 degrees
    Last edited: Dec 23, 2018