Keeping the printer busy

While my primary project focus has been on the OpenAstroTracker, I've been waiting for AliExpress sales to start so I can get all the hardware for cheaper than it all already is. The custom sim wheel is still on the project list but I wanted to test a couple suppliers and parts before I finalise the design. I do only want to make the PCB once since I'm trying to complete this on the cheaper end 😅

An easy test is to build a simpler wheel, in this case a Mercedes AMG GT3-adjacent wheel. The actual wheel is a lot simpler but probably 5x the cost. Milspec wiring and the switches they use are premo and can't be sourced by a normie like me. Which again is counter intuative when there's provsions for switches and they just don't populate them. I digress, my design isn't a replica on purpose, the switches I chose don't lend well to the booted switch ends and would just look messy so I want to make a carbon back cover, somewhat replicating what I’ll be doing for my more complex wheel.

I haven't completely figured out how I want to build the cover but I was thinking of a thin printed shell with the provisions for the heatset inserts and then using it as a plunger into a mould for an outer carbon shell. Another solution is to mould in the inserts in a compression mould. Again, not finalised, Still got a couple iterations I want to do before I go cutting up my carbon supplies.

As you can see I had to make some forced alterations in one of my test prints, I didn't account for the grips riding up to the cover. This has already been fixed for the next test once the current astro tracker parts have finished. I‘m leaning towards making some moulds to cast the grips in a rubbery polyurethane as well. This is really popular in the DIY groups and seems to be extremely durable.

I've also swapped one of the switch positions with a funky switch for some extra functionality. Considering this is for a sim on a computer where you're usually the driver, engineer, strategist and crew chief, you need considerably more controls to manage everything mid race. I still have to design the button surrounds and finalise the button caps as well but I think I have the main plate at a stage where I can send off the files to get it cut in carbon. I would like to attempt it myself but there's an OS supplier than can produce the plate for a tenth the cost of the raw plate on it's own with a CNC, not including the tooling to do the cutting as well, makes it simpler as well as cheaper.

Untill the next project update 😁