Warthog / Cougar mechanical support for FSSB

[Guest]

I thought I’d post a follow-on mod after the FSSB R3 that I did to my stick.

After noticing that the stick moved (where it’s not supposed to move, rotating (for/aft) around the PS/2 connector), I started looking into what was going on. At the RealSimulator site, the suggestion is to tighten the screw that holds the connector housing inside the stick. This DOES work, but without a torque spec, I didn’t like the possibility of stripping that out. It’s fairly cheap metal, so I can’t imagine that the torque spec is very high. Furthermore, during my searching, I read of people actually shearing the shaft from pulling too hard (again, cheap metal). After talking to a Mechanical engineer here at work, I came up with the dimensions of a split collar and he printed it out on our 3d printer (see pics below). I tried to find an off the shelf split collar, but couldn’t find one.
If anyone is interested, I can probably get the solid model for you to print your own or at the very least you’d have the dimensions to make one. I think all you would need is a drill press and a band saw. While a metal version would be awesome, it’s not necessary, considering the required load. Hard plastic or wood would be fine.
Click image for larger version.

Note that in this image I was just trying it out. The final installation has the split arranged down the ‘y’ axis.
You can download the design files here:
https://drive.google.com/open?id=0B4y50yHPnOVeNzRyREZFdlA1VzQ

[Diver]

Good stuff! I’d be interested in model/dimensions! Best, diver

[Guest]

See original post for design file link. I’m sure someone will let me know if it does not work.

[Ssnake51]

Thanks much for the link to the design files. I contacted a 3d printer online and they made a few for me. The mod fits perfectly on the Warthog. Also did try it on the Cougar but I found that the gap was a tad smaller than on the Warthog. Have placed another order for a slightly narrower design. Will follow up when I receive it.

I know I can’t post links to companies on the forum, but if anyone is interested in learning more feel free to PM me.

[AV8R]

Not a bad idea for the overly kinetic input style pilot that puts lots of forces into the stick. I’m one those who are very surgical and never stress the stick much (I use both a stock WHog for WW2 and Cougar-FSSB for BMS). Still, after a time the grip gets some slop w/r/t the connection collar post, due to the single screw that clamps it to the grip clamshell. This slop was solved using this shim:
https://www.benchmarksims.org/forum/showthread.php?26348-No-Slop-for-the-Hawg-Tune-up-for-the-Warthog-SSC

Both the pot metal of the collar post and grip clamshells, and single point mounting are mechanical and material weak links, literally. This neck collar is similar how they keep a human head up after a neck injury, not a bad idea. It may put more stress at the single screw joint however. Worth a try.

[Stevie]

I’ve been wondering how long it would take someone to come up with this…now, to make it round, and make one that fits the 13 degree angled tailpiece!

…and fits under a rubber stick boot…!

[AV8R]

Yes Stevie…

Round and BLACK! (If visible)

And one done such that the grip wobble is gone, and not just the broken neck insurance policy.

[Ssnake51]

I received the smaller neck collars for the Cougar a few days ago. They were just a tad too small and didn’t give the snug fit the originals have on the WH. My fault for misjudging the adjustment needed. Easily fixed however by putting a small strip of electrician’s tape on the collar. Stopped the clunking noise both my Cougar’s were making.
Will have to give it some time and see if it ends up over stressing the single screw joint AV8R mentioned above. Using one of the sticks in Freespace Open - that should give it a good workout.:-)

[Icarus]

@Goblin:

You can download the design files here:
https://drive.google.com/open?id=0B4y50yHPnOVeNzRyREZFdlA1VzQ

I get Google 500 error for that link.

[Stevie]

@AV8R:

Yes Stevie…

Round and BLACK! (If visible)

And one done such that the grip wobble is gone, and not just the broken neck insurance policy.

Yes-Yes…!!!

[AV8R]

Still no response from OP

[Icarus]

@Icarus:

I get Google 500 error for that link.

Its working now.

[Red Dog]

the issue can also be easily resolved internally

these screws holding the stick butt are metrics ones (M3) if i remember well - and they go into the zamac
tightening the screws won’t help at all, it will just make the problem worse

What does work perfectly fine and proven is to replace these M3 screws with imperial screw just bigger, and force them with brute force into their threads
thanks to the minimal difference of diameter and thread and thanks to the relative softness of the zamac, it’s not too hard to do and it’s very stable with time.
I modded all my handles that way a long while ago and none of them ever developped the Y play axis typical of that issue
the hardest thing is to find these imperial screws

[Stevie]

Wasn’t something posted around here on a fix using a chunk of a credit card as a shim?

[AV8R]

Good memory Stevie. Now i know someone read my post
https://www.benchmarksims.org/forum/showthread.php?26348-No-Slop-for-the-Hawg-Tune-up-for-the-Warthog-SSC&highlight=Slop
:blowpar:

Unfortunately the pictures where Photobucket.

[Nigel]

Olivier,
Do you know the size of the Imperial screw?

AV8R,
Two options for Photobucket.
1. You can log into your account and download the pictures and re-post them. No cost but a PITA depending on how many you have posted. If you do that then you could selectively restore threads like this, and it would be much appreciated!
2. I have hundreds of pics and a lot in my build thread so I opted for paying the $6 a month. I did not want to abandon my build thread and I dont hold it against PB for wanting to be paid, it was their original ask of a couple hundred a year that pissed me off. They took so much crap from the public that they relented and came back to earth.