Got some questions while planning a rig...

@Archie Holy cow! I didn't see the shipping price! Think I'll be doing some DIY a la @noorbeast 's FAQ link. Found these conical nuts http://www.ebay.com.au/itm/WNT4701-...83?pt=LH_DefaultDomain_15&hash=item5899f755eb . I've also been looking around 4x4 sites (suspension heim joints), but they're like $60 a pair but include everything (http://www.superiorengineering.com....ch-bolt-stainless-20569?search=rod end&page=2).

@bsft Thanks! Good to know they can take the thrashing.

Daily routine atm is checking the Motion Dynamics site, trawling through ebay, comparing costs of frames vs ease of assembly. Might just teach myself how to weld.

@Trackpad - Have a go at welding if you have the kit to try. I had a MIG welder collecting dust that I bought from Ebay for $99 yeeeears ago.

Plenty of videos on Youtube to show you what to do. I welded my whole frame and it's still going strong. Actually painted my frame last weekend with Gloss Black Enamel and it looks good now. My welds are not a work of art by any stretch, but they hold

Your daily routine brings back happy memories... I was a man possessed during my build. (Still am really...)

If you don't expect much throw on your sim, I actually used reversed locking nuts to give me enough clearance. The nuts have a slight cone at the top and it was enough to give me the movement I need.
Just have them both facing your Heim joint.

If the welds are any better than this
http://img270.imagevenue.com/img.php?image=127319165_IMG_0649_122_527lo.JPG
then you will be fine

As of today, I have every part I require in my possession except for the frame, mounts, tie rods, and motors.

Which gives me about $500 of my original budget to play with for the frame.

In terms of design and costs, I think I'll bump up the budget a tad and introduce additions for flight controls (I've come this far... why not? ).

https://docs.google.com/spreadsheets/d/1KWhCAYLJ7hYY2Pt6lRDEHqtm6xMqTCf0w_nMXdjMX8A

Still here and waiting for the motors to get in stock.

Have spent the week learning how to use Sketchup to create a plan. Spent a bit of time measuring everything and getting dimensions down pat. Making sure I can get 8 degrees pitch and roll (damn pitch... my u-joint is a lil too short. Will need to figure out a way to give the base a bit more height)

Been holding off the steel tubing until I have the dimensions right. Found a place that does roll cage tubing near the raceway.

Slowly getting there.

So the design is kinda like a seat shaker. The lower tubes act as telescopic housings for a smaller tube making up the pedal sets. The steering wheel itself will be mounted onto the larger tube and this too can slide along the smaller tube. This pretty much lets me adjust the pedal and steering wheel position to suit my family. I'll drill holes through the pipe at regular intervals and will hold them in place using unsecured bolts to make for easy adjustments on the fly.



With the current measurements for 44.45mm and 38.1mm tubes (2.6mm thickness - basically, roll cage tubing), I should have about 1mm of play between the pipes. Hope it doesn't rattle too much. The drive rods will be 25.4mm x 1.6mm chromoly tubing.

The tubes facing sideways will be the ones that I can mount a HOTAS setup to if I ever get one.

Can't wait to order the tubes. Will wait til I have the design dialed in with sketchup and sketchyphysics though.

I've also been thinking of the tools I'll need to fabricate these. I think I'll settle for a press drill and a 3-in-1 TIG/MIG/Cut welder. The design doesn't have any angled notches, so I won't need to invest into an angled pipe holder/notcher. And the plasma cutter can double for a steel saw. I've already got a grinder for cleaning up the edges and preparing surfaces. Might buy rather than rent. I suspect I'll need to do repairs on crappy welds... Plus... I might get the urge to make another one or refine the design. The price doesn't seem too bad. About another $700. Which means I'm over my original $1500. At this rate, $2000 is looking more likely.

Yessssss.... the worm drives are back in stock and I've just completed the order.

Aside from that... steel has arrived. All pieces have been cut and prepared. Cutting wheels & hole saws did most of the work with a bit of grinding to make sure everything sits flush. Everything has been cleaned and test fitted. Wasted a small tank of argon on practice welds (maybe not a wasted given how bad they were). Have more coming on Friday. The last piece will be the heim joints which look to be a few more weeks out.

What a project... I've learnt how to use sketchup, cut steel tubing, prepare them for welding, tig welding, and i'm sure there'll be more mistakes to be made and lessons to be learnt (and I'll admit there were times where I thought I should've just spent the money on some aluminium profile). Boy am I glad I live in the Youtube generation.