VPforce Rhino DIY Force Feedback (FFB) Flight Stick Base

For realistic Flight Simulation, a Force Feedback Flightstick is mandatory. Unfortunately, there has been a gap in recent years due to several reasons. For some time now, the VPforce Rhino Flightstick is filling the gap. Due to the long lead time for purchase, this is a DIY Version of the stick base. 

The required motor kit is available for purchase on vpforcecontrols.com (I am not affiliated with VPforce). Compatible with Grips from Thrustmaster, Virpil and more. Please watch out for the correct orientation of the stick connector when assembling the gimbal. The cable opening shall face to the right, as shown on the rendering.

This project is based on numerous predecessors. I took the gimbal design from Gadroc/vpforce-ffb-joystick and modified it for better stability and printabilty. The case is my own new design, avoiding the optical drawbacks of the original plywood concept.

For further references, please visit the VPforce Controls Discord

You can select the gear ratio: the 60/14 ratio is sufficient for most cases, but you can easily upgrade to 72/12 (belt sizes see below).

I have included Gerber data for a small 8 bit Shift Register PCB which can be used instead of the 32 bit board by VPforce for DIY Grips.

See also my Universal Flight Stick Shaft to build your own grip or adapter.

Recommended material is FilamentPM PLA black because of high stiffness (3500 MPa Youngs modulus) and stability (59 MPa tensile strength). Print with 0.4mm nozzle at 0.2mm layer height using min. 4 perimeters and min. 5 top and bottom layers and 25% infill. For gimbal use gyroid infill, for case linear is fine. For the gimbal enough perimeters are important, for the case sufficient bottom and top layers.

UPDATE 2024-06-02: Removed a chamfer on the Stick Connector thread.
UPDATE 2024-06-13: EStop is a 16mm type, not 19mm.
UPDATE 2024-06-13: Gimbal Core Joint had wrong thread size.
UPDATE 2024-06-29: Changed Power Socket to XT60E1-M
UPDATE 2024-07-01: Centering Tool added (thanks, Xaero Zero!)
UPDATE 2024-08-09: Alternative Case parts with M4 heat-set inserts and alternative Base plate with hole pattern compatible to original Rhino (thanks, Xaero Zero!)
UPDATE 2024-01-20: Added Schematic for PCB

Required parts for assembly:

Motors (vpforcecontrols.com)
1x VPforce DIY kit with 2x 57BLF03 motors

Bearings (WaelZlager-24 | eBay Shops)
8x 6802-2RS (gimbal pillows)
4x 6808-2RS (gimbal arms)
2x F625ZZ (stick mount)

Screws (maybe I missed some…)
6x M2.5x6 (PCB mount, Mini Din Socket)
2x M2.5x8 DIN 965 (XT60 mount)
20x M3x6 DIN 7984 or DIN 7985 (bearing retainers, USB socket)
48x M4x10 DIN 7984 or DIN 7985 (case & boot ring)
16x M4x16 DIN 7984 or DIN 7985 (gimbal, boot clamp)
12x M4x25 DIN 7984, DIN 7985 or DIN 912 (pulleys)
4x M4 DIN 7984 or DIN 7985 + nuts (length depending on fan type)
8x M6x16 DIN 7984 (motors)
1x M5x40 DIN 912 (stick mount)
2x M5 washer DIN 125 (stick mount, one on each side of the bearings)

Heat Set Inserts (optional)
44x M4x6x6 (Link)

DIN 912: Standard Hex
DIN 965: Countersunk Philips
DIN 7984: Hex low profile
DIN 7985: Philips, Pozi or Torx

Belt Drive (HKIT-fastener | eBay Shops)
with HTD-5M-60 pulleys:
HTD 385-5M-15W Belt 385mm
HTD 430-5M-15W Belt 430mm
2x 5M-14T pinion

with HTD-5M-72 pulleys:
HTD 420-5M-15W Belt 420mm
HTD 465-5M-15W Belt 465mm
2x 5M-12T pinion

Cover
Car gear shift boot (e.g. from VW Golf II)

Electrics
16mm E-Stop 
2 pole switch 22x30mm (Marquardt 1832.3312)
Amass XT60E1-M socket
2x 10k potentiometer
5 pin Mini Din Socket
60mm 12V fan (any depth)

PCB Connectors
Fans: 2pin JST XH
Joystick grip: 5pin JST XH
Potentiometers: 3pin JST XH