Showroom 2DOF Platform based on on pre-built static rig for flight sims (work in progress)

Hello everyone

I was thinking of building a motion rig for years and after I got a motion rig sim flight as a birthday gift from my wife
the hype was too big to ignore it =)
So after some reading in the forums and thinking about my goal I set some main goals:

ᴏ SimRig will be mainly used for Flying (MS Flight Sim, Elite Dangerous, Star Wars Squadrons) - so I want a moving plattform, no moving seat
ᴏ For budget reasons I will be aiming for a 2DOF solution
ᴏ The result should be well designed and movable on wheels

I am following the excellent tutorial from scruck / SCK Gaming (see https://www.xsimulator.net/community/threads/my-finished-2dof-project-videotutorial.16214/)
with a few twists - mainly the results not being a moving seat.

Before going into the different sections I want to point out that I am using a finished product for the main static rig.
I was actually planing to build the static rig from aluminium profiles as well, but looking for a seat to use i stumpled
over this product and just couldn't resist using it as a starting point. It ended up being completely perfect for my use since
the feet are being screwed in using M8 screws and this perfectly adapted to an aluminium profile frame. But more on that later.

I am completely sourcing from German online stores including Amazon to keep shipping times low and avoid customs problems.

I will use one section for each main part and update the progress on the go and insert pictures as well - I hope this helps in following the progress.

I will keep this as an overview thread but I am happy to go into detail an each part - feel free to ask


Static Rig:
ᴏ Sourcing - Done
ᴏ Mechanical Build - Done
ᴏ Attaching controllers and testing - Done




Bass Shaker:
ᴏ Attaching bass shaker to static rig using wooden plate - Done
ᴏ Testing with Sim Shaker for Aviators and Sim Shaker Wheels - Done
Next Steps:
ᴏ Attaching Amplifier in convenient place on finished rig



Frame of motion rig:
ᴏ Sourcing (aluminum profiles + angles + universal joint) - Done
ᴏ Building two main frames with aluminium profiles - Done
ᴏ Mount universal joint - Done
ᴏ Mount wheels on lower frame - Done
ᴏ Join the frames with universal joint - Done
ᴏ Install static rig on motion rig - Done







Motors and electronics:
ᴏ Sourcing - almost done, open: Arms for joining motor shaft to ball joint. Shipment date: November 21st
ᴏ Installing hall sensor - done
ᴏ Adapting hall sensor with pulley wheels (3D printed from parametric CAD file!) and timing belt - Done
ᴏ Test wiring using Arduino Uno + 2x IBT_2 drivers - Done
ᴏ Testing motors and hall sensors with SCM3Utils - Done
ᴏ Setup emergency stop using two relays - Done
ᴏ Mount motors and electronics on aluminium frames - Done
ᴏ Mount motor arms and ball joints - Done
ᴏ Test and tune motors using SCM3Utils - Done
ᴏ Setup FlyPT Mover configuration and test communication with finished motor rig - Done
Next steps:
ᴏ Fine Tune filters in FlyPT Mover

Placeholder Reply for future use

Thanks, I was expecting something like this, but couldn't find the info about editing posts (also not in your link)

So I finished assembling my universal joint and connected my frames with it but I'm not too happy with the results for two reasons:
- Available angle for movement is very low
- The weight is held from the side and only one side per one profile

I thus decided to order four new, longer profiles to mount on top of the lower and below the upper frame. So I'm posting these pictures here since they are not part of the final result.



Also started assembling the electronics on a wooden plate and ordered relays for my emergency stop, updates on this coming soon.

Huge steps going forward, updated my initial post with all the new pictures and new accomplishements.
Now I'm stuck waiting for my motor cranks. Ordered from Xometry but they let the confirmed delivery date pass and now are avoiding giving me a new one. Will try and order from a local supplier directly, hopefully this won't take weeks, since I now have a 95% finished sim rig sitting in my man cave, crying to be tested....

This looks great, in the middle of my build waiting for parts. What size aluminum profiles did you end up going with? Size and type. My prototype looks like your but still deciding on profile sizes for lower frame. I am estimating 300 lbs loaded with rider and gear.

I am using 40x40 mm profiles from Amazon. I could get them ready cut in 100 mm steps for around 18 € / m which is crazy cheap.
It’s from a German company so I don’t know if the link will help but you can see the type of profile used:
SCHMIDT systemprofile 1200mm Aluminium Profil 40x40mm Nut 8 Strebenprofil Anthrazit 4040 Alu Konstruktionsprofil 1,2m https://amzn.eu/d/8PAYRFS

Cool, I'm designing my own simulator and will take some inspiration from your awesome work.
40x40 profiles seem to be the right choice

thank you - will be happy to answer any questions you might have

Finally got my motor cranks and spent a lot of time mounting and fiddling with the positions of all components. But I can finally say that the basic setup is DONE!
Just finished my first test flight in MSFS with FlyPT Mover which was really a bumpy ride even though I put huge filters on everything but I need to get the hang of how to translate the positions into my small windows of available movement angle.
Anyways, I will keep on testing and update here - but my first impression is: WOW!

I have a few questions:
1. what voltage do you supply the motors with ? The original design used 18.5V what voltage is yours ?
2. could you share the files for printing the gears ?
3. do you have no problem with IBT2 burning and would you show the settings in SMC3 ?

Nice. Start. Im starting to build mine like yours with alum. profile. Just asking where did you get your u joint? Ive been searching everywhere except the scrapyard.