How do you construct a throttle (the actual grip and lever)?

[1./KG4_ArthurMimo]

Recently someone was chatting about building their own throttle (quadrant). I've built control boxes with digital push buttons and analog potentiometers before, so that part of the process is clear to me. 

 

So I have a couple of questions  regarding not the programming but the construction of a throttle inside the quadrant.

 

1) how do people create and mount the big throttle handles? I can't imagine that you just glue a piece of plastic to a sideways mounted poti  (although on the X55, it looks just like that?).  The question is especially relevant to me in regards to linear (sliding) potentiometers. These must slide along some kind of rail, since the actual potentiometer in these cases would be way too small. But then you have to find a way to translate the movements of the big handle on the big rail into small increments on the small sliding potentiometer. How do you people construct these things to work reliably and not fall apart?

 

2) the throttle handle - these often look very professional. My first instinct would have been to just take some metal pipes or bicycle handles but that would almost certainly look and feel bad. Can these handles be sourced anywhere? 

 

3) having buttons on the throttle handle. These are tremendously useful. B

The next question is a direct follow-up. Many commercially  available throttle quadrants have buttons on the throttle lever itself. That is tremendously useful. On photos of the X55 interior, is looks as though the manufacturer just has a bunch of cables running from these buttons to the inside of the quadrant. But won't the constant back and forth of the handle cause excessive wear on these cables, causing them (and the corresponding buttons) to fail eventually? 

[Sokol1]

1 hour ago, 1./KG4_ArthurMimo said:

 

1) how do people create and mount the big throttle handles? I can't imagine that you just glue a piece of plastic to a sideways mounted poti  

 

 

Don't attach throttle lever direct in pot axis, pot will be forced and last little. Use a flexible coupling in between, e.g. a pieced of rubber hose.

 

For use contactless sensor your lever need bearings in pivots for minimize play.

 

Look at GVL224 mechanics to see a good example of construction (better than commercial -Tm, Saitek, CH, solutions).

 

For use linear pot's, use R/C ball linkage between throttle lever and pot lever. Know that will be a little difference between lever circular movement and pot linear movement.

 

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2) the throttle handle - these often look very professional. My first instinct would have been to just take some metal pipes or bicycle handles but that would almost certainly look and feel bad. Can these handles be sourced anywhere? 
 

 

 

Maybe  some  real aircraft parts in eBay (expensive).

 

But throttle grips can be made in several ways - depends on your skill and tools available, e.g. PVC, aluminum tubes - a bicycle handle made in steel will be difficult to drill for additional buttons. In 3D Print repository are samples for print.

 

Sample: https://www.thingiverse.com/thing:1810592/

 

Other, a right hand grip for TWCS:

 

https://www.reddit.com/r/HotasDIY/comments/8h29eo/lefty_throttle_3d_print/

 

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3) having buttons on the throttle handle.

 But won't the constant back and forth of the handle cause excessive wear on these cables, causing them (and the corresponding buttons) to fail eventually? 
 

 

 

Just use flexible cables and route then well - commercial throttles (e.g. X-55/6) use poor solutions in this matter.

 

 

Edited August 12, 2018 by Sokol1

[1./KG4_ArthurMimo]

Dear Sokol1, 

 

Thanks a lot for your input! I had not seen that 3D printed throttle but that's a great resource.

 

I know very little about mechanics but the bearings you mentioned look exactly right. I'll go and do more research. Thanks!