Yes, it took quite a while, but was done in stages. Overall, not as much time as you’d think. I was willing to invest time, but money was the limiting factor. The whole budget was less than $500! The goal of my project was to build a cheaper and better alternative to off-the-shelf motion rig and controls. I wanted something that is not just much much cheaper (because I couldn’t and wouldn’t want to afford at lest $4500 to buy the equivalent but worse system), but also modular and easily convertible to yoke+throttle / joystick+hotas / cyclic+collective configurations and to any aircraft I’d feel like flying.
It started as a way to save money and being able to afford a real motion rig, but ended up being IMHO better than anything that can be bought off-the-shelf for my particulate use case.
So I designed the motion rig that has exactly what I need, and the controls that are built for VR: Instead of modeling a specific cockpit, they are very compact, and have different encoder and switch shapes for easy tactile feedback. By feel I know exactly where my hand is at any time, around the encoder box and switch box. The throttles are 737-inspired and have the authentic design and feel, including analog reverser lever axes, TO/GA and T/A disconnect buttons etc. but hey also have prop and mix levers which can be selectively operated left/right engine by holding a yoke hat switch left or right.
Dual encoder box controls the entire functionality of GNS550, and also most 737 autopilot panel knobs and buttons, and analog instrumentation like heading bug, nav/com radios etc. Other systems like G1000 have partial control for obvious reasons (touchscreens and sideline nav buttons). In any case, I have most controls at my fingertips at all times, so almost the entire flight can be done without using VR controllers or mouse. GA planes have everything covered by my switchboxed from cold and dark state. Airliners would need controller/mouse interaction during FMC setup and some of the engine start-up, but after that, almost everything is also covered by my cockpit.
The main thread with videos and more details is here, and all design files and part lists are available on my website.