Showroom Barry's Racing Sim - IT'S ALIVE (with motorcycle capability (sometime in the future))

The kind of keyway style fitting we're thinking of doing might be slightly different. The motors I have are hollow shaft so we're thinking about machining one single piece with a 6mm center sticking out one end to attach a flex couple to (for the pot) and on the other end possibly a square to press fit the lever onto (Interference fit). I'd like to hear from others who had the hollow shafted motors. Maybe the hollow part can be removed easily? I need to have a closer look.

Something like this below, with or without the bolt on the end. Less welding, and less parts to connect maybe?

Would there be any chance of the threaded bar and nut method slipping due to the fast movement?

"no chance" of slipping isn't 100% the case, Especially when your dealing with traction loss. This is what happens when the main bolt loosen's a hair and you start getting slop in the system but aren't clued into exactly whats going on and the end result is something like this. Set screws were "pinching" the Threaded rod with Flat spots i had made, Then had a Rather thin 4-40 bolt and nut.....Main Nut must have been a hair loose, Snapped the 4-40 bolt then it was riding on the set screw's which did all the damage. I remade the Threaded rod, Welded the Lever back on, Went with a 5-40 bolt this time and the same set screw's pinching the Threaded rod, No failures so far.

That's always part of my worry when using threaded bar as in most cases it's not very hard.
I have a friend with a lathe and a mill which is why I'm thinking the square end might be the answer.

Here's my basic front section of my frame.

My PCB edge holding clips have arrived from Farnell.

Middle frame cut tonight. I'll weld it up at the weekend.
72" x 22" so it's not too wide. I'm looking forward to this part as I'll be able to mount the 2 frames together and get a better idea of how it'll work. I'll be getting my motor mounts back from the engineer as well.

I've also cut out a small frame for the side of the top part to mount my gear shifter on. I hope that works. I was wondering if most people screw their steering wheels to wood or metal as I haven't quite decided yet. I've left the space free so I have options.

Motor mounts done.

JRK PCB side mounts.

Cool stuff! I like watching the progress.

Test fit of the circuit board holders tonight. That's all I got done really.

4.5mm drill bit is perfect and a 2.5mm surface seems to be about perfect depth for the clips to go through. I ordered some sheets of 3mm ABS plastic so where the clips will be I'm going to shave half a milimeter off the back with the router. The 3mm should be nice and rigid and will be good to mount the JRKs on and should also be easy enough to make some sort of box out of which I can mount a fan or 2 on as well.

That shaft slipping is my same issue. I think Im going to just either buy simexperience or new gear boxes with the key way. Im thoroughly frustrated with all of the little fixes that i have to do hear and there. 360 Hall sensors saved me from breaking pots at least. I tried dirlling the bolts and they just ended up shearing in half.

I'll be speaking to my engineer friend tomorrow about getting the shafts made. He's been making parts for motors and hydraulic systems for 15 years so I have full confidence he'll come up with something solid that works.

Threaded bar (even high tensile) will always be weaker than a solid bar through the middle. Then when you drill it, it halves the torsional strength at least. My idea is to make a shaft in one piece with a 6mm stud on one side for the flex coupler to fit, and a square or something similar on the other end. But ultimately the goal is to make the gearbox the weakest point.

Pics are above of my measurement. It's pretty much bang on 12mm internal diameter. However, we may create a interference fit. That'll be down to the judgement of the engineer.

Well I somehow torched a JRK last night so I think that means I dont need one and am going to break down and buy a damn simexperience kit.