AH-64 Collective grip

This is 3D model for AH-64D collective grip I created based on dimensional drawing I found online. I originally created this so I could have my own collective grip for DCS. This design includes all buttons and switches  found from real grip, excluding lower trigger guard and chop-button guard. To pair your grip, I've released a design of base unit for this.

I have used this by myself for a year and grip is still functioning as it should. 4-way & 2-way switches design may not be as good as they could, but they've worked well enough so I haven't bothered to design better version. Note, that you may have to tune your pushbuttons (pinky-buttons) clip and/or sleeves, so that whole switch won't get pushed inside grip while using.

In real AH64D collective stab control switch is a 2-way switch, but you can install a 4-way switch for it's place and gain 2 extra buttons.

This build requires some technical knowhow, but it is not impossible to print & assemble (heck, even I was able to do it!). Since my knowledge in electronics is subpar, I won't release any instructions on that topic, but below you can find my list of components I used on my build.

Here is list of bought components I used and some tips for your assembly process:

Hardware:

• I suggest using M3x10 countersunk screws build, I used M3x15 but it is unnecessary long for most cases.
• For stems in 2 way and 4 way switches I recommend using M3x15 for higher tensile strength, but M3x10 might work as well.
• I used paint marker to highlight embodied text next to the switches. I flooded letters with white paint and cleaned excess with towel and alcohol/nail polish.
• To clamp grip tightly to what-ever-pipe you are attaching it, I used M6 thread inserts and M6x8 hex screws. I embodied thread inserts into plastic with soldering iron.
• All switch hats and cursor are just press fit on stems.
• For assembly I highly recommend  having good pair of tweezers or slim needle-nose pliers to help your assembly job.
• You can glue grip shell's parts together so, that you end up having only two parts to line up when closing the grip up. I glued my upper & lower sides together on each sides, and then made the final assembly. Do not glue left & right side parts together, if you want to be able to take your grip apart later.

Electronics:

• Tactile switches for all switches are same 6 mm x 6 mm x 4,3 mm tactile switches from Digi-key. I used these, but any other with same dimensions will work just fine, tactile feedback will just vary depending on the model. 
• For search light toggle switch use 6 mm ON-OFF-ON switch or similar
• For triggers' return springs I used spring from clicky ball point pen which I cut into length.
• As there are quite a lot of switches in the build, I used two shift registers in this build.
  • Install these registers inside the grip, below each switch plate.
• For cursor axes I used similar minijoystick they use in PS & Xbox controllers
• I used STM32 Blue pill development board as my interface to my computer. I used tool called FreeJoy to configure it, and I found it very easy to use.

2 & 4 way switches:

• Depending on what kind of tactile switches you have, you might have to cut excess “legs” of the switch when installing into switch body/housing.
• Body/housing part has tight tolerances, so print with high quality, and be careful pushing tactile switch into it's place.
• Once all tactile switches has been installed, install drop stem between switches.
• While holding the stem, screw M3x10 or M3x15 screw into stem from the bottom, as seen in pictures above. 
  • Do not tighten the screw all the way, leave small play and test how the switch feels. This can take some time before tactile feel is good.
    • It is good practice to make sure that tactile switches close the circuit when using the stem to push buttons of tactile switches.
• Once you have adjusted the screw tightness, use 4pcs M3x10 screws to install assembled on pushbutton plates
• Last push switch hat on the stem, mine has held in place with just press fit.
• Boresight/polarity switch is assembled similarly, it is just held in place with 2 screws and must be screwed from below.

Pushbuttons:

• All different sizes are assembled same way
• I'm being honest - these are bit pain to assemble
• First install tactile switch into bottom of the housing
• Install button sleeve into relative hole in grip
• Slide “button” part into sleeve from below, slim section first so that the “button” can't fall through
• Slide housing on the sleeve. Make sure, that slits on the housing align with slits of the sleeve.
• Push clip on slits of the housing. You should get small “Click”-sound when in place.
  • You may have to rotate the housing slightly to have it properly aligned with sleeve.

Printing

Here is couple of tips and thoughts of mine to successful print:

• Use PLA. PLA is know for it's ease of printing, and it is strong enough for this application.
  •  As a  material it is more rigid than PETG, so you will have sturdier feel for the grip. (Elastic modulus for PLA = 3,1 GPa, and for PETG = 2,9 GPa)
  • However, if you are to sand these parts, then you should use some other material.
• Print grip parts facing the mating faces on print bed. This ensures good quality on mating faces and reduces gaps and other imperfections.
• Use support. It might be possible to get this print done without, but supports help a lot on complicated geometry. 
• If you are using speedy printers (bambu etc), try to slow down if you encounter problems.

Notes:

I will update these assembly instructions as needed. Feel free to comment and give feedback on my design.

Changelog:

• 19.3.2025 Updated link for the shift register
• 6.1.2025 Added note to install shift registers inside the grip
• 17.2.2024 Updated grip parts after receiving feedback. Modified parts has new revisions and are reuploaded. 
  • Added some features to make top grip parts stronger
  • Adjusted screw holes sizes
  • Modified L lower to better fit search light toggle switch
  • Reuploaded assembly step with these modifications

• 14.2.2024 Added some more information about printing parameters 
• Added link to base files
  
   

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