I used G27 pedals with the Nixim brake mod for many years and although they worked fine I wanted some top mounted GT style pedals to hopefully get a better feeling of immersion so I decided to make my own.
For the main structure, I used 50mm x 50mm and 30mm x 15mm aluminium box section and 10mm stainless steel rod with some fairly sturdy collars to hold it all together. I looked at a few designs online and produced a basic CAD design in Sketchup although I did change a few things during the build:
The CNC g-code files that I used:
Although I used a CNC machine for some of the parts, as aluminium is very soft they could easily have been cut and drilled by hand with a basic power drill and a hacksaw.
For the electronics, I used the Leo Bodnar BU0836-LC Load Cell Joystick Controller which has a single load cell interface and multiple inputs for analogue devices (eg. potentiometers and hall sensors) and digital inputs for buttons and switches.
The load cell I used for the brake is a 0-30kg model bought from China which results in a fairly light pedal so I may swap that for a higher rated model in the future. The model I have is a Shenlen SL602 which is wired as:
For the clutch and accelerator I initially used A1302 Hall Sensors which are contactless and in theory should maintain a smooth operation over the long-term. However, in use I found the hall sensors didn't stay properly calibrated so I decided to replace them with potentiometers (ALPS 10k RK09711110K) and traditional linkages which is working great so far.
Choosing springs was mostly trial and error. I ended up with:
This is one area where you may need to try different springs to find some that you like.
The pedals are fully adjustable for separation, reach and stroke but as I always left-foot brake in games I spaced them fairly equally although it would be straightforward to set them up for heel-and-toe.
I don't think these pedals have made me any quicker but they do feel a lot more like driving a real car than G27's so are good for improving immersion at least.
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