Open SimRacing Handbrake, CAD files. Cheap construction. AS5600

Welcome!

This project is opensource and I upload all cad files. You can upgrade code or print files to make it fit your parts.

You can make CUSTOM HANDBRAKE LEVER. I made it with a 14x3 trapezoidal thread, so you can make it longer or create a completely different lever design. 

Today we are making DIY handbrake for your setup. I made this model because handbrakes costs too much for me and i need just simple handbrake not super realistic version. I used parts that i had already but they are easy to get and cheap.

AS5600 is optional. Lever should work without it. 

First be sure you have those parts:

1. 100-200g of PETG or PLA

2. M3 Screws 8-10mm x6 / 35mm x1

3. M5 Screw Any head type 40mm long

4. RP 2040 small waveshare type. I have original waveshare but probably any copy from ali should work https://www.waveshare.com/rp2040-zero.htm?sku=20187

5. AS5600 magnetic encoder (with magnet!) (Optional but recommend).

6. End switch Something like this(version with metal lever) https://www.flyn.to/PutmLRO

7. Some cables.

8. Type-C cable

9. Spring ~25mm long ~9mm wide wire thick ~1-1.5mm

10. Tools like Tin and Hot iron. Allen key. 

Assembly

I won't lie it can be tricky. Take your time don't rush. Print all parts before assembly.

1. First solder everything like on this illustration with wires: 

   

2. Put AS5600 on cover, pressfit don't need to be glued but if its loose use some double sided tape or glue.

   

3. Glue wires like on this photo. This step can be skipped.

   

4. Mount RP2040 into its slot. Use hotglue or tape. Don't use too much, you will maybe need to resolder something.

   

5. Assembly leverspring and spring and M3 x 25mm. Screw M3 x 25mm all the way and put spring on. I don't have exact photos. Red is spring blue is M3x25mm screw. 

   

1. This part is hard. First Tape lever with M5 screw it will be easier to assembly. And put everything like on photo.

   

   

2. Let's calibrate endposition. unscrew by some turns M3x25mm screw by using designed hole in front and put switch and pull lever all the way back. Switch clicks? Nice. Check if not too early. Switch didn't reached? Unscrew a little and check again.

   

1. If switch clicks let’s install shaft support. Screw M5 all the way in, but not too hard it's a plastic thread, and unscrew 0.5-1 turns it needs to turn freely with lever. Put support on and use 2 front holes to screw in 2x M3 screws 8-10mm. 

   

2. Put Magnet on M5 screw end, securing with tape or hotglue.

   

3. Plug in usb cable and install circuitpython to pico ver 10.x https://circuitpython.org/board/raspberry_pi_pico/

4. Paste code.py and main.py to your device.

5. Unplug device from PC (DON'T PLUG IN AGAIN)

6. Install and secure side cover with 4x M3 screws.

   

7. Plug device again to PC. Wait a while. Pull lever until end switch clicks.

8. FINISH! Check if everything works.

(srry for gif quality i needed to compress a lot)

Sorry for not detailed as I want to be instruction. I will maybe updating this in future.

ENJOY YOUR HANDBRAKE!!!