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Gimbal Project

14 bytes added, 17:57, 17 January 2012
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<br/>Jentron&#39;s design is perfectly usable in it&#39;s configuration, but I needed
to modify it for use with the DIY Cockpit Project.<br>Besides, I&#39;m a geek and
no self respecting geek can resist fiddling with things. :)<br/p><p>Below is instructions on how you can construct this gimbal for use in your
Here&#39;'s information on how my version of the Jentron Gimbal Mk II was built and how you can build your own.</p>
<br/>One important thing to note - the gimbal is designed to be mounted underneath
the cockpit floor.&nbsp; This is what it looks like from above, in the
&quot;operating&quot; position:<br/p><p>
This article will only cover the ins and outs of the gimbal itself. The
reason for this is that your application may be a bit different and you'll need
to adjust other parts of the design to fit your situation.<br/p>
<br/>Two &quot;fancy&quot; tools are going to be required to build this project.&nbsp; <br/p>
* 1 Step Drill. This is used to enlarge the end holes in the single-gang extender box.
<br/>A cheap 1&quot; Step Drill can be had for less than $30. In case you're not
sure, a step drill looks like this:</p>
[[file:step_drill.jpg]]<br/p><br/>Here's a list of some other common tools you're going to need:<br/p>
* Hacksaw -or- a pipe cutter. Pipe cutters work better for cutting EMT.
* Vice or vice-like device
<br/>Materials needed to build the gimbal box:<br/p>
* 1 each single-gang electrical extension box
in the electrical box and then drill out the ends using the 1&quot; Step Drill.
The hole needs to be large enough to accept the threaded portion of the 3/4&quot; EMT
connector. When you&#39;re done, the box should look like this:<br/p>
Next up, you&#39;re going to have to use your vice grips (2 pair if you have
them!) to position the 3&quot; &quot;T&quot; bracket on the side of the extension box.&nbsp;
The best way to do this is to measure 1-1/2&quot; in from the end of the &quot;top&quot; of the
T brace and draw a centering line.&nbsp; Measure the electrical box along its
long axis and mark the center of it.&nbsp; The centering lines ensure that
you&#39;ll correctly position the &quot;T&quot; bracket on the side of the box.<br/p>
<pbr/>Position the box and T-Bracket like this:<br/p><pbr/><img alt="Illustration showing the correct placement of the T-Bracket" src="t-bracket_position.jpg" width="400" height="307" /><br/p>
<p>With the vice grip(s) holding the t-bracket in place, put the box in a vice
to hold it down.&nbsp; You&#39;re going to use a 1/4&quot; drill bit to drill holes in
with one another.&nbsp; The portion of the bracket that sticks out will be the
support for the stick stub.&nbsp; It&#39;s got to be as close perfect as you can
make it.&nbsp; In the end, you should have something that looks like this:<br/p>
<pbr/><img alt="Illustration showing both &quot;T&quot; brackets in place" src="both_brackets_mounted.jpg" width="400" height="307" /><br/p><pbr/>You&#39;ll notice in my drawing that I&#39;m using screws to hold the brackets in.&nbsp;
This was done because I didn&#39;t want to take the time to draw a reasonable
looking pop rivet. :)<br/p><pbr/>The last step is to mount the 3/4&quot; EMT fittings.&nbsp; These hold 3&quot; sections
of 3/4&quot; EMT conduit that act as the pitch bearings for the box.&nbsp; It&#39;s
important to get these as tight as you can.&nbsp; They&#39;ll take all the force of
the stick moving fore and aft.&nbsp; I recommend using a pair of Channel-Lock
pliers and a vice to make sure those fittings are as tight as you can make them.&nbsp;
If you&#39;re paranoid and have a welder, it couldn&#39;t hurt it to weld them in place.&nbsp;
With it all assembled, it should look like this:<br/p><pbr/>
<img alt="Completed gimbal box" src="complete_gimbal_box.jpg" width="400" height="307" /></p>
<p>I didn&#39;t include the nuts that go to the EMT connectors on purpose.&nbsp;
They MUST be used. :)<br/p><pbr/>Here&#39;s an exploded diagram that shows you how it all goes together:<br/p><pbr/>
<img alt="Exploded illustration of the gimbal box" src="gimbal_box_exploded.jpg" width="400" height="307" /><br/p><pbr/>The last part of this assembly is the stick stub.&nbsp; The stick stub is
made from a 7&quot; long piece of 3/4&quot; EMT that has had two holes and a notch cut in
the bottom.<br/p><pbr/>A PDF file of the part drawing is available
<a target="_blank" href="stick_stub.pdf">here</a>.&nbsp; The completed stick
stub should look like this:<br/p><pbr/><img alt="Completed stick stub" src="stick_stub.png" width="640" height="491" /><br/p>
<p>The stick stub is just that - a stub.&nbsp; Your flight grip and lower stick

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