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The progression. DIY Pedal system from scratch

Discussion in 'DIY peripherals' started by kanuk, Mar 24, 2018.

  1. kanuk

    kanuk If it ain't moving, it ain't simulating...

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    The master cylinder is a girling wilwood type 0.7 bore and readily available in any speed shop or even EBAY. The caliber I’ve used is a Yamaha Rhino / TRF front calliper. You should be able to use any caliper as long as it holds a decent volume of fluid. Smaller calipers may not have enough travel in piston movement to emulate the feel we look for
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  2. kanuk

    kanuk If it ain't moving, it ain't simulating...

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    @SeatTime
    I agree. I’m an electronics engineer by profession and trust me that is one of my most endearing qualities... self awareness and self critique. And I happen to always let my friends try out my projects so I can surmise it’s effectiveness.
    In the meantime, boundary pushing, is my adventure
  3. ferslash

    ferslash Active Member

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    and... h0 did you cut the metal parts... laser cuting?
  4. kanuk

    kanuk If it ain't moving, it ain't simulating...

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    @ferslash
    No ferslash. I used an orbital jigsaw (one that moves forward and backward as well as up and down) with an acrylic cutting blade (fine toothed) and drill press with a template.... take your time and it will be ok. I now have friends asking for sets too so I may be running a batch through a router or a laser....
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  5. EvanMelanson

    EvanMelanson New Member

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    @kanuk

    Care to share the make/model for that jigsaw? I plan on doing a similar pedal project and have been looking for cheap alternative to cut the metal myself.
  6. kanuk

    kanuk If it ain't moving, it ain't simulating...

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    @EvanMelanson

    Of course! Its a Ryobi one plus. Though I'm not quite sure if you would be able to acquire that particular model or brand in your neck of the woods. Any decent orbital jigsaw would do. I know that Milwaukee amd DeWalt do one as well...
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  7. EvanMelanson

    EvanMelanson New Member

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    I found a decent selection for around $100 CAD. That seems reasonable to me.
  8. Haraguchi

    Haraguchi Member

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    Wow !

    What is it ?! Super professional its construction!

    I'm going to base this project, for who knows, one day I can do something, about 10 light years away. haha


    Congratulations !!
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  9. kanuk

    kanuk If it ain't moving, it ain't simulating...

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    Thank you @Haraguchi

    playing with the pedals last night whilst designing the heel plate I decided that the spring mechanism in the clutch was a little too aggressive for my liking. Mind you, not that I don't like it, just that it was a little snappy and no adjustable free play or dead zone at the beginning of the pedal press. So I decided to build the newer design shown on the Protos and yes indeed, I think this is that 'goldilocks, 'just right' type of result!
    And I completed the potentiometer for the throttle and clutch with its linkage....

    20180404_231738.jpg


    The roller system with flanged bearings. No run out, no drop offs and solid as a rock!

    20180404_231522.jpg


    A couple of pics of the second clutch mech completed...

    20180404_231630.jpg

    20180404_231453.jpg
    • Like Like x 3
  10. kanuk

    kanuk If it ain't moving, it ain't simulating...

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    @EvanMelanson
    That is very reasonable indeed. Tools like those are pricey down under. I think even the ryobi cost me in the region 250 or so....
  11. ferslash

    ferslash Active Member

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    mmm. i am seriouslly thinking about buying a jigsaw... would you share your pedal templates? (if not i totally understand) :D
    best regards and congrats for such a nice pedals

    fer
  12. kanuk

    kanuk If it ain't moving, it ain't simulating...

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    @ferslash
    Hey bud.
    The jigsaw is very useful and if you plan on cutting up aluminium I would recommend it. Unless you happen to have a table router bench which would be even better ;)
    In terms of templates I would have to document everything very carefully in order for you to understand the myriad of steps I had to undertake, the umpteen number of 'on the fly'modifications that had to be done, and the god knows how many variations that happened on fusion 360 in order for fitment and compliance and I'm still developing them day by day. I am happy to help though if you need it so PM me and if this is a journey you wish to undertake I shall than simply be the best advisor I can be... :)

    Oh, and thank you so much for your very kind words!
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  13. Jerry Atrick

    Jerry Atrick this is my sim Gold Contributor

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    Hi Kanuk, what a fantastic build; I suppose its now time to enjoy your craftsmanship and give those peddles a workout!:cheers

    Regards Jerry.
  14. kanuk

    kanuk If it ain't moving, it ain't simulating...

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    Thanks @Jerry Atrick

    I wish I could get down to business with them but there are a few little details left that I have to finalise. Nothing major, like running cables and deciding on a plug system so that it's easily maintained if needs be etc. But soon sir, soon.... :D
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    Last edited: Apr 7, 2018
  15. ferslash

    ferslash Active Member

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    @kanuk
    (thanks for your response :D) so... about the tools needed... the jigsaw cuts aluminium, but... i i want to use a cheapo plain sheet of metal, would it do the job... or the jigsaw only cuts aluminium (wish i guess is softer)

    best regards

    fer
  16. Alexey

    Alexey Well-Known Member

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    You can cut metal if you do it slower and use cutting oil. I have done this myself and it works. Also sometimes you can actually get blades designed for metal cutting.
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  17. kanuk

    kanuk If it ain't moving, it ain't simulating...

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    @ferslash

    Here's the thing. Like @Alexey said, you can use steel but make no mistakes about it, the scope just got that little bit harder. Steel is not quite as friendly or 'pliable' (I use this word loosely) as aluminium and things like rounding off corners, drilling holes, countersinking etc. are just so much easier to with aluminium due to its inherent nature. You want to get a radius edge on steel, take a file or a grinder to it. With aluminium you take to it with a sanding block, some 240 or 320 grit and a few seconds later you have a somewhat controlled gentle radius on the corner... I mean I also used a grinding wheel and belt to do my radius needs but i chamfered all the edges to the housing and the pedals using sandpaper held at a guesstimated 45 degree angle! And whilst it wouldn't measure up on a micrometer to be anywhere near perfect, the naked eye can't tell...

    And a jigsaw will do much much more work cutting steel mm for mm compared to aluminium. As suggested cutting fluid is necessary , which I used whilst cutting up all the plates and drilling all the holes. Just makes it easier and prolongs the life of the cutting / boring tool.

    So, I would try to acquire aluminium (it isn't expensive) and if you didnt want to play with 5mm like I did, drop to 4mm (I would not recommend 3 mm, too much flex). Whereabouts in the world are you? Is there a reason you don't wish to use aluminium?
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  18. ferslash

    ferslash Active Member

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    @kanuk thanks for your kind response... :D i live in Mexico, i do can get aluminimum, i got a quotation last year to cut some aluminium vs steel, and it costed like two times the steel price... but i might be something related to the lasercut company... i will try some aluminium (also it looks grate)...

    so... my first step will be to buy a jigsaw... (this forum push my making skills little by little... i like that) :D:D:D:D
  19. kanuk

    kanuk If it ain't moving, it ain't simulating...

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    @ferslash

    :D

    fabulous! there should be aluminium available so shop around. Get your tools and materials ready and then we can begin!
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  20. kanuk

    kanuk If it ain't moving, it ain't simulating...

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    I am now taking care of the minute details. I decided on a 3.5mm stereo jack and socket to make the connection so I designed and sliced up a case to hold the socket for the pedal housings and also a cover for the potentiometer so that it isn't exposed and vulnerable to prying / curious / accident inducing / clumsy / derpy hands! :D

    socket1.jpg

    socket2.jpg

    This will enable me to just unplug and unbolt each of the pedals individually should they need repair or maintenance or knowing me, upgrades (as I cannot sit still)
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