33 Button Box with Rotary Encoders

Controlling your car in a sim using the keyboard isn’t ideal. Too many keys you don’t need placed to closely together to operate by feel. Taking your eyes off the road long enough to find and press the right key often results in unwanted off-road excursions. A button box with which control all the things that need changing during a race is a much better solution.

So, I’ve been looking at amstudio’s sim racing button box for over a year, but just got a’round tuit. Didn’t buy a box. Front panel is leftover acrylic sheet I had lying around the shop. This thing ain’t gonna be pretty, but it’ll work.

Probably should have painted it before installing the switches.

This is actually a complete rewire after I’d totally botched it the first time. I messed up the grid, and after trying to fix it three or four times, just ripped it all out, figured out the correct layout on paper, and did it right.

I suppose I could have painted the panel but I plan on using more than one layout and decided to just slap a overlays on it.

Sliced up a 2×4 to make the sides of the box.

Continuing the “use junk already in the shop” theme, I re-sawed a piece of 2×4 to create the sides of the box. Planed them smooth, cut bridle joints, then assembled and glued the frame.

Smooth and planed to uniform thickness.
The glue up.
Turns out the front panel was slightly out of square. Shooting board took care of that.

I did have to tweak the panel a tiny bit as the frame was perfectly square, but the panel was off by a few thou. Then added some blocking to support and mount the panel.

Glued in some corner blocks for mounting the panel.
Added blocks in the middle to stop the panel flexing, then cut and glued in a piece of scrap 1/4″ plywood for the back.
Might not be pretty, but it works just fine.

I have a few small bits of 1/4″ plywood in the scrap bin, so that’s what I used for the back and part of the stand. The stand uprights were made from the pine cutoffs from the foot stool I made for my wife a while ago.

Screwed together a bracket and screwed into the “cockpit”.
And it works just fine.

And there you go. Installed and working. The overlays seem to stay on just fine by laying them over the switches. These are card stock. When I finalize the layouts I may go with something heavier and some Velcro to keep it in place.

Used the Illustrator panel layout to create a template for holes for all the switches.

It’s a bit of a PITA to cut out the overlays with an X-Acto knife, but I only use a couple different switch layouts. I’ll eventually print up a nice one once I’m happy with the switch layout and retire the hand written in pencil layouts I’m currently using.

Check out amstudio’s video for a the software for the Arduino. All I’ve changed are the limits to include one more switch.

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