Diablo2112's 4-axis SFX-100 build

Yes, yet another SFX-100 style build. I'll post info, pics, and progress here, along with a few tips I've learned along the way to help others.

First, if you're not familiar with the SFX-100 (and you should be, here on xsimulator), It's a D-box type, 4-actuator DIY simulator developed by a colloboration out of Germany. You can find many videos online, and the project website at https://opensfx.com/documentation/

I ordered parts according to the guide. In my case, orders arrived in 2-3 weeks. My recommendation is order your 3D printer first. This is not nearly as intimidating as it sounds. 3D printing is tons of fun. After much research, I ordered the Prusa i3 MK3S. Took my about a half a day to assemble this.

My pre-project rig is below, along with a few pics of my build progress. Placing the threaded M10/M8 "reducers" (i.e., inserts or helicoils) was the toughest part. I found if you use an 11mmx1.5mm tap threaded in 6 turns or so, this greatly eased installation of the inserts. Don't thread the tap in any further, you want the taper of the tap to help firm up the insert when fully installed. Works a charm.

So, here you go. A few pics of my progress. More to come. I'll be replacing the RSeat N-1 chassis with an 80:20 modular to mount the actuators.

Another tip: you want your 3D printer to be built absolutely dead-square. For the Prusa, if you're dead square, you'll get a message at the end of calibration that says congratulations, your axis are perpendicular. If you don't get this message, somethings wrong. I took great care in the intial assembly stages to the get the frame dead-level.

Here's another. Use RC Tire glue to fix the o-ring to the 3D Printed bumpstop.

Motor controller wiring and mounting. This can be rack-mounted on a standard 19" rack if desired.

Actuator assembly is nearly complete. Spent a few hours today setting up software and a bit of tuning in Simtools. I'm using Thanos AMC-AASD15A as the primary controller for this build, instead of the standard Arduino.

Among the advantages of Thano's controller is built in calibration of each actuator. I consider this a nice upgrade over the Arduino, which doesn't know the position of the actuator, and can cause problems if you turn that system on in any position but fully retracted. I'm also building an Arduino/Shield as an alternate controller.

Some testing of the software and controller. Simtools + Thanos AMC-AASD15A controller. I've set this at fairly low levels for testing purposes. Sim is PC2.

Thank you for your great feedback on the controller!

And here is the other video with manual test from the AMC-AASD15A panel buttons:



Thanos

I just want to commend Thanos for his controller setup. This build has gone super-smooth, and the software side has been painless. Thano's controller has worked great, truly plug-n-play. I didn't need to do any controller wiring, just connect the Thanos controller with DB25 M/M cables to the motor controllers, and to my PC via a standard USB cable.

Simtools has tons of options for tuning, and the Simtools FAQs are detailed and walk you through the process of setting up your rig. Between Simtool and Thano's controller, I've been able to accomplish a nearly complete SFX-100 build in less than 25 days, from sourcing parts to getting a running system. My last bit is waiting on an 80:20 rig from SimLab to mount my actuators and finish my build. I'll keep pics and videos coming as I progress.

A warning for those having their 3D parts printed. Early on in my SFX build, I explored having a vendor produce the parts instead of printing my own. I figured even if I print my own, I'd have a spare set of parts. I ordered 1 set of complete parts, and scrupulously provided the requirements for the build (0.25mm layer height, 8 perimeter layers, 12 top/bottom layers). I just recieved the parts from this print, and they were incorrectly printed. They're useless.

I cut open the motor mount to show this, picture below. On the left is the part recieved. On the right is a part I had made which I aborted mid-print due to bed adhesion issues. Note the differences in perimeter width. The part on the left is flexible and bends; the part on the right is much more solid. The printing parameters for SFX parts are critical. Make sure you get the proper parts.

Wow this looks terrible... did they print with two walls only to get it done quicker?

I think that's exactly what they did. To their credit, they did provide me a full refund when I pointed out the problem.

Mounted the motor controllers in a dedicated case. I'm space-limited, and need a kitty-friendly solution to keep prying paws away from exposed circuits. Plenty of space still in the little closet holding the PC, and the 6U case here does the trick.

Other progress: Thanos has a great set of STL files to print a beautiful case for his controller. The pictures don't do justice to how nice this little case is; perfectly fits the controller's 3 boards, each with built in supports.

All 4 actuators are done, now just waiting on delivery of the 8020 parts to build the rig.

The SFX-100 actuators are limited to 100mm of stroke with the commonly used Simfeedback software. The physical design allows for a 110mm stroke if desired. Thano's controller lets you set this as an option. 10% more range here if desired (especially useful in Simtools for keeping your axis allocations below 100%).

Great job!!

I think you might want to set the LCD contrast on the controller, use the little potentiometer above the screen to adjust that. It can vary depending on the USB voltage.

Thanos, thanks! I have set the contrast. The controller normally sets back behind the glass in my case. I’ve adjusted the LCD contrast so I can easily read the screen when sitting in the simulator; I didn’t bother to adjust for this picture, that’s all.

Tearing down the old rig, my trusty RSeat N-1. Great rig, and has served me well for over 3 years. 8020 incoming to mount the actuators.

Some of the gear waiting for the new install.

I've finally got the base layout on the 8020 rig together and mounted the actuators. Looks great, and super-solid. I'm still waiting on a few more parts (4080 extrusions for cross members and the wheel deck), but what you see below is still more than solid. The rig fits great in the space we have.

Tidy up the wire runs. Still a rats nest of wires at the back of the computer, but that will be fixed once I mount more of the gear on the wheel deck. Working great, too. Been testing on No Limits 2 (Roller Coaster sim) as I don't have a wheel for inputs at this point.

For now, I'm keeping the NLR v3 chair. My intent is to map heave, pitch, and roll to the SFX-100 and surge and sway into the chair. Works fabulously on No Limits 2; the heave is really fun in VR on the coaster sim.

Wire runs from the rig to the control cabinet.