Bergisons Making Of

Flight Controls (throttle and stick)

As much as I was impressed with the quality of Thrustmasters Hotas Warthog stick and throttle, they didn't feel like real flight controls. So an improvement was due!

Coming up with a plan for the stick. Coming up with a plan for the stick.
The first cuts. The first cuts.
Welding skills are still OK. Welding skills are still OK.

Using big enough ball bearings... Using big enough ball bearings...
... to achieve reasonable sturdyness. ... to achieve reasonable sturdyness.
So far, no problems. But then... So far, no problems. But then...

Finding a solution for the correct ammount of resistance, displacement force and damping, proved very tough! Finding a solution for the correct ammount of resistance, displacement force and damping, proved very tough!
I tried different combinations of springs, gas-springs and dampers... I tried different combinations of springs, gas-springs and dampers...
... without obtaining the desired results. Either the force was too strong, or the centering too unprecise. ... without obtaining the desired results. Either the force was too strong, or the centering too unprecise.

Some setups would made the stick jump when moving it a little, others just felt sluggish. Some setups would made the stick jump when moving it a little, others just felt sluggish.
After A LOT of trial and error, I settled on a combination of regular springs and motorcycle oil dampers. After A LOT of trial and error, I settled on a combination of regular springs and motorcycle oil dampers.
That and some added centering mechanisms provided the perfect feeling of a real control stick! That and some added centering mechanisms provided the perfect feeling of a real control stick!

It is light around the center, with increasing forces towards the outside. It is light around the center, with increasing forces towards the outside.
It moves small amounts without any jumping and always returns to its center when released. It moves small amounts without any jumping and always returns to its center when released.
This a video on the making of the throttle and stick.

 

Scorpio posted on 03.4.2020 at 12:20

Having had the pleasure of flying your sim, I can only underline how realistic the sensation is - you think it and it's done, no translation necessary. You did a great job on the controls and watching your work on it continues to amaze me.Thanks for sharing!


 

kenneth ayers posted on 20.2.2020 at 22:02

can you please go into more detail about how you made the electronics work. i am trying to build my own but have not come up with a suitable solution. thank you

Bergison

Hi kenneth, I did not modify the electronics at all. Just original warthog parts. If you mean the hall sensor for the stick, then look inside your warthog stick casing and build a mechanism that moves the magnet over the sensor in exactly the same way and distance. You can see the way I did this in the video and on the pictures. If you meant something else, or need further help - contact me!

 

Regic112 posted on 15.3.2019 at 23:05

Hey there Bergison! 
I recently discovered you and your awesome creations, I know you said you aren't looking to divulge your secrets regarding the G/Motion-seat you've made since you are looking for a production company. I was wondering if you would be willing to give out schematics for your stick system? It's incredible and I can probably figure out how to reverse engineer it from your pictures, but I figured I could ask for schematics to make it a bit easier lol

Bergison

Hi Regic112 and sorry for the late reply! I just saw your post here (there must have been something wrong with the email notification for new posts...).

I am afraid I have no decent plans or blueprints of the stick to share with you because I developed it while building it. As I said in the video, it was more of a trial and error, try this and that approach, rather than following a straight design.

If I can be of any help with your own build, let me know. And share some pictures please!