Building(?) a set of rudder pedals?

Greetings!

I have several sets of flight controls that are, (mechanically), Pieces Of Junk.

For example, the one that works the best is a Saitek, (Logitech) X52 HOTAS that has a messed-up twist-rudder.

I would like to bring out the three leads and connect them to a home-brew set of rudder pedals.  Electronically, that’s something I can do, no sweat, even if I have to use shielded cable for noise suppression and a filter network on the leads.

My questions are about the mechanical aspects of rudder pedals.

Assuming a “generic” set of rudder pedals, (as opposed to a set for a specific aircraft), that would be (more or less) universally applicable.

  1. What is the “mechanical throw” of the pedals?
    (i.e. What is the movable distance from the “front” to the “back” of the pedal’s motion?)
  2. How much resistance should the pedals offer?
    • Should they move freely as if they were on ball bearings?
    • Should there be some friction? If so, how difficult should they be to move?
  3. Should they self-center?  Or should they “stay where they were left”?  (i.e. Just flop around.)
    • I am assuming that, at least in flight, air pressure would have both a tendency to center the rudder pedals and give them a bit of resistance.
  4. What should the general shape of the rudder pedals be?
    • Horizontal bars?
    • “Brake-pedal” shaped?  (i.e. Horizontally mounted rubber pedals?)
    • Foot shaped?  Perhaps with a heel-stop?
  5. Is there anything else I need to know before I waste time and money building something that won’t work?

I’m not worried about toe-brakes yet.  Actually, I’ll be jumping up-and-down if I can get the rudder part of the rudder-pedals working.

Thanks!

1 Like

Hi,
There are TONS of rudder pedal designs out there that a search for “DIY rudder pedals” will yield. From super simple to not-so-super simple.
I started with a pair of used Saitek combat pedals. Replaced all the “slidey” parts with bearings which changed the whole feel of the pedals. Then I threw a 12v motor on top to provide force feedback. All of this took a 3d printer though. I saw a design recently that used nothing but general hardware store materials. So, the answer to your question lies with you. What do YOU want, what can you afford, what tools do you have at your disposal, and what is your ability level?

2 Likes

I’ve done that in the past and they’ve been super-complex and, (as you mentioned), require a 3D printer which I don’t have.

My basic design is probably going to be a set of wooden sliding frames on a wooden base, using two pairs of ball-bearing drawer slides for the motion.

I am also planning to use some #14 stranded steel guy-wire looping around a pulley connected to the front of each pedal’s frame. I will have to come up with some kind of gear arrangement, (depending on what I can scrounge), and (possibly) a multi-turn potentiometer to provide the electrical signal.

I also have two unused axes on the Saitek controller that I could use for toe-brakes, (assuming that I can get to the circuitry for those axes.)

I strongly suspect that they’ll end up as a McGyvver’d monstrosity with the professional charm and grace of an outhouse.

Hey!  I just thought of something.  I can pretend I’m flying a 1930’s home-brew aircraft that used a broom-handle for the stick and whatever they could find off of junked cars for the pedals, other controls and the cockpit instruments!

P.S.
Is there a “cobbled up out of lawnmower spare parts, steel cable and barbed-wire” Beta Participation classification? :rofl:

If you are trying to do this for a zero or close to zero cost, I recommend taking a trip to the landfill metal pile. An old bike can provide with (most) everything you need for your project. Small gear from the back wheel of a 10 speed, bearings, brake or gear change cables, and tubing. A $10 Arduino clone and mobiflight can provide the electronics.
If you go to the landfil, remember to take a tool kit and some throw away stuff because they weigh you both in and out, and you can’t weigh more on the way out.