DIY SIM from wheelchair parts

Hey all! Inspirited by @Halloween2go I'm going to build my own compact model motion sim with old wheelchair motors. I got all the materials and equipment to start and I will also try to create my model in 3D.

Racing chair which I did use in a stationary setup. Steering wheel and paddles from Logitech combined with a Xbox One will be my starting point. Later on I will probably use a computer.

I've got a small welding machine with a very small co2 bottle, but I want to try to use flux core wire. I'm going to use mainly 40x40x2 mm steel tubes.

Probably will start with some welding and adjust it later in the 3D model. Some things are easier to make a mockup than designing everything in advance. I've got several parts from the wheelchairs laying around, so I'm still figuring out or I will use it or not. Like this tilt mechanism and the motor mounts.

My now idea is to have a multifunctional motion sim, so I can tilt the chair back for a more F1 position. Still have to find a way what to do with the paddles then. And I need to try it on the frame because it's extra weight to move. My motors have a 1:25 ratio and I will use 25amp power supplies.
First I will create the basic frame before using the extra tilt function of course.

Extra input and idea's are welcome!

Hi @Design89,
I'm collecting the parts to start building my 2DOF flight simulator.
I've ordered two 250W 75rpm wheelchair motors and I believe that they are pretty standard for that purpose due to the fact that while searching I've found many similar products with the same characteristics.
Are your motors 250W 75rpm?

I've 2 different types of motors, 2 of each type. One says 0.235kW 96rpm 12.5A and the other type 0.33kW 216rpm 17.5A.
I was thinking to use the 17.5A ones for 2DOF and the 12.5A for traction loss.

Last weekend I did take the wheelchairs apart to see what's useful to use. Motor mounts look really nice to use.
And there is a pivot point which I might be able to use as a pivot between the lower and middle frame. It's just a copper ring without a bearing or something.


My first test to get some movement with the Arduino en IBT_2's. Just used 2 motors for now.

And I'm not sorry for my test setup, this is what I had laying around here.

I will start working on the frame soon. I will keep you posted.

Time for some frame work!

First I made the base frame, based on some dimensions from @Halloween2go
With those dimensions I had a good start to create my own frame based on myself.

Only thing I was nog sure about was the height for the top frame, as I want to use this rig also as a flight sim.

I'm trying to figure out the maximum angle the U joint can do.

After I decided to make it like this and I did some test fittings. I came to the conclusion that the U joint should be at least a lot higher, or even directly under the top frame.
As it is now, the center of gravity moves too far outwards, allowing it to topple over.

So don't make the same mistake as me!
Have a look here also: https://www.xsimulator.net/community/faq/universal-joint-placement.108/


For now I will have a look with everything in place and see or the motors can handle this. Otherwise I will chop it down.

I made some levers from some scrap I had, but this cannot move the upper frame in it's maximum position.

So I took some other scrap and screwed them on the original wheel spacers from the wheelchair. If this works I will need a real good seatbelt to keep me in the chair...

Thanks @noorbeast really helpful information.

Got all the wires hooked up, what a job to do.... @noorbeast I fully agree on your signature line!
I did use a proto shield on my Arduino, so it would be easier to hookup all the ground and + wires. And also the green wires can be soldered together. Seems pretty easy to use if it works...

Here are some pictures of my setup so far.


I made some mounts for the hall effect potential meters 180 degrees.

On the 220V side I did use a basic electric box with clamps for multi core and one core wires, easy to hookup.

The 220v power plug is going with 3x 2.5mm2 multi core to the electric box. From the box to the power supplies I did use 3x 2.5mm2 single core wires (as used in houses to the wall sockets, ect.) Because the box and the power supplies are mounted on the ground frame, so this will be stationary.

From the power supplies to the IBT_2's (mounted on the mid frame) I did use multicore wires again, because the mid frame is moving. Single core could brake over time.
And for the motors I could use the original sockets from the wheelchair. Only the middle one is adjusted because this was the socket for the batteries and the cable needed to be a bit longer. This is for my traction loss motor.

I did use a proto shield, looks easy to use and soldering the wires like the green ones.
The only thing is that it does not work at the moment, after a lot of testing, trying and reading here on the forums, I came to the conclusion that my IBT_2 are not working right.

At the moment even my Arduino doesn't work anymore.. I will order new IBT's and an Arduino, start from scratch and try with 1 motor at the time with a small breadboard.

Yes I've got some movement. Unfortunately one IBT is already broken, turns in only 1 direction..
Could be some power delivered back from the motor? Or the IBT has both bridges open at the same time?

Also when I pull the line in SMC3 down, the motor will make a strange noise. Is this normal or could it be a bad motor?


For safety I did only test with a 12V battery instead off the 24V power supply.
I want to put some capacitors in parallel with the motor to protect the IBT when I'm using the power supply again.

One motor at the time in SMC3 at the moment. I did replace the motors and those don't make strange noises... Still wondering what that could be though.


It's way to high like this. Don't think the motors can handle the weight when fully equipped. Still testing with one 12V battery.

Thanks, I wanted to have it this long for flight simulator games. But now I know for sure it's way over the top and indeed the motors can't handle levers that long.

Would you @noorbeast have any idea how to fix this problem?
https://www.xsimulator.net/community/threads/how-to-protect-your-ibt_2.17590/#post-235082

Thanks. Only problem is that I have one 12V battery and my power supply's are 24V.
Running the motors on only the 12V battery works for testing, but it will not be enough to run my rig.

Did some work yesterday on the height of my rig. Uni joint is now almost directly under the top frame.
Yes, that pole on the left is what I did cut out. Could still give it more height if needed with some square tubing.


Also I did angled out the motors and I want to try something else with the pivotal point.
Welding with no gas wire, needs a lot of cleanup with it welds pretty easy.

Works perfect. It's just a copper ring, it was used on the back of a wheelchair as pivot point for the suspension.

Hi were you able to solve the problem of IBT2 breaking down when powered by 24V? I'm building a motion sim with 24V 75RPM motors and I hit the same problem I already broke 2 IBT2 units.

In response to the IBT2 issues, it may sound obvious but I haven't seen it mentioned in the post anywhere, but are you aware that the motors may have electronic brakes on them? I have some near identical motors, 24v 75rpm and some of them turn through the brake when powered but some don't. The brakes do hold them in position when powered off which is great as they are also a similar ratio and therefore not self locking. Just a consideration to ensure the controllers aren't being overworked.