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$2 USB Optical rotary upgrade for most joysticks

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griffindodd:

Well this 'cheap' mod is getting a bit expensive, but being able to fab my own parts is essential so...



griffindodd:

I haven't had time to fab anything tonight as we had friends over for dinner, but I did make this template for the switch support plates. One with a 3/8 diameter hole which should fit over most stick shafts and a second to sandwich around the locking collar of the sprocket I am using. This will sandwich the cog wheel and switches in a nice small protected channel and stop the switches from rotating at all. The slot runs along a mounting bolt off the joystick mounting plate.

Artwork edge size of this image should be printed at 3" x 3" for true scale



BadMouth:

I wandered around Lowes for a bit last night looking for cheap parts to repurpose.
Spent $4 on various pieces to try as a coupler between the encoder and joystick shaft.
Wasn't really happy with any of them.  The closest thing was a nylon spacer that I'd have to drill to accept a set screw.
Ended up ordering a pair of these of fleabay:
http://www.ebay.com/itm/6-35mm-x-6-35-CNC-Motor-Jaw-Shaft-Coupler-6-35mm-x-6-35mm-Flexible-Coupling-0-/251049730539?pt=LH_DefaultDomain_0&hash=item3a73bae1eb
Now I have to wait weeks for them to come in.  :(

I'm still looking for something that could work as a yoke (or whatever you want to call the part that links the encoder to the post on the side of the joystick)


I have some 1/4" ABS that I could cut them out of.  Also considered cutting them out of project circuit board (would make mounting the encoder easy).
But I'd like to find something already slotted that anyone can buy and use without having to do much cutting.  Oh, and it should only cost a couple bucks.  :P
I've seen a paper clip used, but would like to have something more substantial.

Any ideas?

griffindodd:

Yeah I'm having the same issue with that part.  Just spent an hour with the dremel screaming away at some rolled steel to make my own.

griffindodd:

Did a little this morning before I left for the office.

Made the mounting plates, not too pretty but they are steel so they will be super durable


Here's how they assemble around the sprocket with the microswitches sandwiched inbetween, I've ordered some more suitable switches but they are coming from the moon, or China or somewhere that takes about 3 weeks so I'll have to wait on those before progressing.


This is based on this idea of using two lever arm microswitches in place of the on-off-on momentary switch that gave me concerns about longevity.


One of the advantages of this design is that it could be a completely self contained sealed unit with just the wires to connect and the lock collar to attach to your joystick shaft

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