heres some pics of the custom tron handle insides I made (FYI)

[soslo]

well, I wanted the trigger plus 2 thumb buttons...and neon glow wire of course. The problem was making a hollow handle that worked with a happ joystick base.

So, after about 2 weekends of long days and many trials, I found a solution that works magnificently.

Pieces required:

12" of 1/8" galvanized nipple (hollow threaded on each end)
1/2" to 1/8" galvanized reducer coupling
1/2" PVC coupler
1/2" by 2" sprinkler riser

1. cut the nipple to length with a dremel.
2. sand down the outside ever so slightly so it will fit into a joystick base
3. use dremel to add a groove for the c-clip
4. screw everything together
5. sand the pvc coupler down to fit snugly inside the Tron handle
6. assembly your tron handle and run the wires through your new hollow joystick

the sides of the Tron handles screw into the riser for a tight fight. (use 1/2" or 5/8" screws)

The handles feel super tight - no wiggle at all.

Pics to follow

[soslo]

fits perfectly in the handle for a tight feel while playing

[soslo]

run the wires through. I could barely fit the 3 button wires, the ground, and the 2 neon wires.

[soslo]

here is a picture of the handles installed on their new home

[soslo]

and finally here is a poor picture of the handles glowing

[Metimbo]

Wow!  Those look great!  Good job!
~Tim

[Frostillicus]

wow bit of engineering there, I'd never think of stuff like that.   Very cool.  Nice cammy, too

[soslo]

Thanks Frosty  

I am very happy with the way the Cammy panel turned out with the trackball mount hidden and the ball right in the palm of her hand - you do very nice work!

[1UP]

Why did you have to sand down the riser?  I used a 1/2" male-male (ABS?) riser that fit inside the handles with no problem.

What diameter was the nipple?  I find that 3/8" OD pipe fits into a Happ super joystick base perfectly.  How is the nipple attached to the reducer coupling?  How do you keep the stick from spinning around in the base?  Any problems with the coupling coming unscrewed?

[soslo]

1up -

Why did you have to sand down the riser?

I didn't actually sand down the 1/2" sprinkler riser - I just sanded the 1/2" PVC coupler between the riser and the galvanized reducer/coupler.

I used a 1/2" male-male (ABS?) riser that fit inside the handles with no problem.

me too

I painted the whole thing black - otherwise you'd be able to pick out the dark grey riser and the white PVC coupler (I should have stated that above).

What diameter was the nipple? I find that 3/8" OD pipe fits into a Happ super joystick base perfectly.  

The nipple diameter was 3/8"  - but being galvanized it had some anti-rust coating that made it a *tad* larger, which wouldn't allow it to fit into the Super base without *a lot* of coercion. I ended up making about 6 handles/bases because I broke too many in the process with hammer/vice. Yeah - I get frustrated some times...

How is the nipple attached to the reducer coupling?

With a regular 1/2" PVC female/female threaded coupler

How do you keep the stick from spinning around in the base?  

Friction  Actually, I was going to rig up a stop, but the wires were pretty tight and I taped everything well, so the handles resist turning fairly well. Of course, if someone really wanted to, they could spin it 4 or 5 times and pull something out...

Any problems with the coupling coming unscrewed?

No, that thing went on very tight (like plumbing should). It was actually very tough getting everything apart. You know how it is when you are engineering something for the first time - trial and error up the wazoo. I have full confidence in the handle strength...the felt quite stout after assembly was complete.

[Tiger-Heli]

Nice job, looks good!