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Star Wars Cockpit Renovation

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clarkey View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote clarkey Quote  Post ReplyReply Direct Link To This Post Posted: 12 Jul 2019 at 1:10pm
Loving this thread, great work/read.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote wim outrun repro Quote  Post ReplyReply Direct Link To This Post Posted: 13 Jul 2019 at 7:52am
GREAT work on this cabinet. And all the pictures of your work. I just enjoy it.
Cheers wim outrun
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bods Quote  Post ReplyReply Direct Link To This Post Posted: 15 Jul 2019 at 1:25pm
Thank god another weekend of crap at work is over, just hate it, so good to get back to things I enjoy
 
The main shaft it turns on for the left/right I had drilled the holes in it same as original SW yoke, took some work to get them in the same place on the collar, wanted the original to fit also in case it needs replacing, then cut it down to same length as SW one, it was longer because it was welded inside the RB wheel box In 2 places for strength, the collar on mine is deeper though so I should of cut it a bit longer but doesn't matter, taped the threads for the screws, had to file and sand it down a bit more to fit then to get rid of the weld areas
 
 
 
 
The bearings I wasn't sure what size being American Imperial, don't want expense of buying from USA all time in future so bought these off ebay UK, there same size inner diameter, outer is slightly bigger and also they were longer so I cut them down.
 
These are Bronze Oilite bushes/bearings. my dad knows all about them being engineer, Oilite being company name and registered, basically they already have oil in the bronze, I had no idea till he told me, but I've found out how they work, they are impregnated with oil, when I was cutting them down with the angle grinder, that warmed them up and the oil started coming out with the heat, so obviously that's how the operate, as the shaft running through them is turning and heating it up it lubricates it, pretty amazing really
 
 
 
 
WANTED! Buggy Boy Junior Rear Seat. Continental Circus Cockpit Lower Rear Light Plexi and more space
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bods Quote  Post ReplyReply Direct Link To This Post Posted: 15 Jul 2019 at 1:35pm
There seems to be some different types of SW yokes, the handles from this RB has 2 hole in each handle, but also a bigger hole in the middle of them, think that is for roll pin, as the holes look original and painted inside. the left handle had a bolt put through because the original bolts had snapped off, the right side had one broken off too
 
was enough of the bolt inside to get pliers on it and with some wd40 and some heat I got them out, has extra holes so part threads on one is missing but the bolts still work so didn't attempt welding them up as I could make it worse plus I don't have Imperial Taps to redo the threads. You can get the new shafts anyway in rebuilt kits but keeping cost down
 
 
 
 
 
WANTED! Buggy Boy Junior Rear Seat. Continental Circus Cockpit Lower Rear Light Plexi and more space
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bods Quote  Post ReplyReply Direct Link To This Post Posted: 15 Jul 2019 at 2:28pm
Every day for  2 weeks I kept thinking I'd finished and could get all the metal to the powder coaters, then think about something I hadn't done, the last thing was stripping paint off the handles, so wish I'd got Sandblaster setup but still trying to sort that. the left handle had bolt going through it so I had to fill it in with some alloy repair, no one local sells anything like it again so ebay and wait for it to arrive, though the seller was quick
 
 
 
 
 
 
 
WANTED! Buggy Boy Junior Rear Seat. Continental Circus Cockpit Lower Rear Light Plexi and more space
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Post Options Post Options   Thanks (0) Thanks(0)   Quote iamjimmi Quote  Post ReplyReply Direct Link To This Post Posted: 15 Jul 2019 at 2:52pm
Nice factoid ref the self lubricating bushes... 

The last yoke I rebuilt, I removed and replaced the bushes. I thought I had screwed them up because when I inserted the shaft it was locked solid. I had to grip it with mole grips and force the shaft up and down (fnarr fnarr). After a little while, it all freed up until the shaft was soon moving completing free of resistance.

From what you have described, sounds like the movement forced out the impregnated lubrication.

I don't think I have ever written a post with so many potential double entendres!

  
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Wurstkopp Quote  Post ReplyReply Direct Link To This Post Posted: 15 Jul 2019 at 3:20pm
LOL
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bods Quote  Post ReplyReply Direct Link To This Post Posted: 15 Jul 2019 at 4:56pm

LOL just need to remove the part about the yoke rebuilt and It could be open to all sorts Smile

Most of these parts a pretty worn apart from those 2 new bushes, you don't want sloppy second hand ones, just to add a few more
 
maybe they are quite tight when new, probably worth just putting a bit of oil on to get it started. I did wonder how if they have oil into the bronze how that worked but after heated up it just starts running out, assume the Capstan bearing/bush in old Cassette players are same, they must be bronze too but same type
 
The main box looks better than I thought it would after being painted, thought the welding might look worse but not too bad really, powder coaters let me down again, left handle isn't done properly at the top, wasn't happy with last lot of work from them so I'll have to look for someone that can do the job properly next time, can't be bothered driving back up there to complain
 
Was a good job I remembered to drill the holes in bottom plate for Springs before taking up there, not sure if I forgot to deburr the holes for the cover but other than that all good
 
 


Edited by Bods - 15 Jul 2019 at 4:58pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bods Quote  Post ReplyReply Direct Link To This Post Posted: 15 Jul 2019 at 10:57pm
It was nice to finally be able to start assembling after all the work. I still need to get some parts so I can rebuild the original SW Yoke, for now I've used the big gear, the medium size gear, return springs for handles, clips for the shaft so need to add the cost of those to the build of it
 
Need to work out what it's cost me so far to turn this RB controller to the SW Yoke, all the metal was free, costs so far is Powdercoating but that's divided up with a coin door set, SW roof metal and Original Yoke, so probably about £17.50, as total £45. pair of Bushes about £7, and 4 gears the 2 smaller ones from ebay seller which was £28, only need one set for it but got spares, so £14 to get this working so around some bolts and repair for handles probably looking at £50 which isn't too bad as well as it looking like new
 
So old original bushes could go back in
 
 
 
Main shaft bolted in place
 
 
Cleaned up the springs
 
 
RB ones weren't that worn, didn't get the use Star Wars did I guess
 
 
Fit the new Bushes in the sides, could hammer them in but have the press so might as well use it, then remembered they go in from inside controllerSleepy 
 
 
Socket sets always useful for these things too
 
 
Ends of the springs go through the holes at bottom and shaft through springs
 
 
And the Gear
 
 
Stopper pin through the spring hooks and shaft and bolted in place, gear bolted in place and clips each side of the bushes
 
 
The Bumper stops on both controllers were gone, just the metal left so I had to find something I could use so not spending more money, had these rollers from old machines at work, very similar thing but bolt is smaller I can fit through, so I found some tube and fitted those in the holes so now correct size.
 
 
 
They do the job and the machines don't get the daily hammering they did back when new
 
 
Main shaft and springs are same, end of springs through the metal, shaft through springs and bolt through hooks for return
 
 
1st part of handles bolted on
 
 
Gears on after washer and clip
 
 
WANTED! Buggy Boy Junior Rear Seat. Continental Circus Cockpit Lower Rear Light Plexi and more space
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bods Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 2019 at 10:10am

The Thumb buttons on RB had been replaced with these square buttons, not much I can do but reuse them, wanted to get them apart to clean contacts and also the springs are a bit strong, have a drawer full of old springs but non suitable, got some from old machines at work and made them a bit thinner which has done the job

 
 
 
The SW one had a Trigger lever missing as well as Thumb Button, so I bought a block of Nylon plastic and cut out to Triggers to use in this one. It's not easy stuff to work with as filing it doesn't work that well so took quite a while
 
 
 
 
WANTED! Buggy Boy Junior Rear Seat. Continental Circus Cockpit Lower Rear Light Plexi and more space
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bods Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 2019 at 11:41am

Didn't think ahead again when I came to the wiring, already has the same connector as SW but missing cables for the extra Pot and others 2 short so found some Alarm cables and took out the red, white and black wires and some heat shrink to to make up the cables. reused pins from other connectors so all free again

 
 
 
 
I hadn't thought about the wiring because I have other plans with the controller, but wanted it to look and be wired up as an original SW yoke so it could be used on original cab, had to move the pins around, could do with proper tools for pin removal but use old radio aerials which does the jobSmile
 
 
 
 
 
 
 
 
Can't remember if this had springs in the handles for the triggers, think it did but couldn't find them, so again my draw of springs had nothing, so thinking cap on again, looked at pens and found a spring that's double length needed, so I cut in half and used one each side which is perfect
 
 
 
 
 
 
 
 
 
 
 
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bods Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 2019 at 11:49am

With controller done I ordered some artwork from Arcade art Shop Smile 

 
 
 
Finally machine playable with proper type Yoke Controller, still have work to do on the cab refitting the front panels which are all altered so that's next but great to play it while I do more work, also need to make the cardboard screen shroud
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Wurstkopp Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 2019 at 12:18pm
Pure arcade porn! Absolutely amazing work! Clap
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Post Options Post Options   Thanks (0) Thanks(0)   Quote muddymusic Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 2019 at 1:33pm
Incredible work dude. Completely recreating missing parts is next level stuff. In other hands this would have been way too much for someone to restore...most impressive.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote yorkshire_spam Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 2019 at 1:48pm
Fsking awesome! Top effort dude.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote backflipper Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 2019 at 2:59pm
Well done! 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote namfreak Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 2019 at 3:39pm
I think we can all learn something from this great Jedi Master 

That yoke recreation is a work of art in itself. Absolutely superb!


Edited by namfreak - 16 Jul 2019 at 3:40pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tb2000 Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 2019 at 3:45pm
Nice work indeed! I like those sets of jaws for your vice to turn it into a mini bending machine! Asked my dad about those (him having been a draughtsman/toolmaker and then car mechanic) and said he's never seen any! I assume you've had them a while, they don't look new?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ianski Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 2019 at 4:14pm
Superb progress on this, well done. Looks like you'll turn your hand to whatever needs doing which is commendable. So nice to see lots of resto pictures and plenty of write up Clap
Looking forward to more updates and seeing this come together.

My cabs: Track and Field, Mr.Do, Pacmania, Space Ace, Gorf, Jungle King, Astron Belt, Gyruss, OutRun, Frogger, Defender, Return of the Jedi.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote stevebm1 Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 2019 at 4:52pm
so how far did you get the first time you played it?,it must have felt great playing it in a cockpit
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