Mini joystick project (2013-09-12)

[Yvan256]

I need a smaller-than-regular but bigger-than-Grayhill-04A-B01 joystick for my CNC remote and future mini-arcade projects, so I've decided to try building a mini version of a Seimitsu LS-32, Zippyy or similar joysticks.

The idea is to design something that can be built like a sandwich with layers of CNC-cut panels.

Here's what I have so far:
- bottom plate made of 2.8 mm thick expanded PVC
- small microswitches with levers (E-switch MS-085-05-01-F045-S1-A, part EG4540-ND on Digi-Key)

Here's two photos of the bottom plate, including a CompactFlash card for size comparison.

[severdhed]

very cool, i can't wait to see these

[ids]

very cool

want

[Yvan256]

I cut the top plate yesterday, all I need now is a way to build a joystick shaft, ideally with a smooth half-sphere pivot. The best idea I had so far was using a drilled nylon acorn nut, resting on the edge of the round hole of the top PVC plate. I'm not sure what the durability of the nylon will do to the PVC plate, worst case scenario I'm guessing I'll have to cut the top plate again to allow the insertion of a nylon washer to make contact with the nylon acorn nut.

Other than that, a joystick is just a shaft with a spring. I'll be using a ball top since it's going to be easier to find a small round ball than a tiny bat top. And I also need to find eight tiny bolts to secure the switches together with the two plates.

[Buick455]

I might be way out in left field but what about something like this http://www.plasticballs.com/delrin.htm cut in half, or just drilled through the center. I don't know if there is any thing to worry about with PVC on Delrin though. Delrin on Delrin would be ok, so if all else fails you could get a piece of delrin to re-make the top plate.

Neat little project

edit:
I just had another maybe cheaper solution idea pop into my head.. You happen to have any PVC ball valves? maybe the ball can be removed with surgical precision, lol.. I think its proven in PVC valves to not break down (quickly anyhow) and those are water tight tolerances.

[Typefighter01]

Considering the short duty cycle, I wouldn't worry about PVC to Delrin, Delrin to Delrin, etc., just use what ever material is available.