For those of you who are interested in the load cell project mentioned a couple of pages back in this thread, here's another brief update on where things stand:
I spent all of last week working on the electronic packaging for my "pre-production prototypes" built up and ready to deploy to my beta testers.
The V2 bracket looks pretty nice -- it's made of heavier gauge steel so it's more solid and has less flex, which will allow it to be used with a wider variety of load cells (meaning if you want one that requires more pressure, this bracket should accommodate that). This isn't the final production version of the bracket, but it will give me a better idea of how sturdy the load cell package is when I distribute it to my testers.
Unfortunately, I've hit a snag with the electronics packaging. I've been trying to find solutions that will keep the price point as low as possible, opting to use existing load cell amps and some custom wiring and a cable coupler that will mate with the T500RS pedal cable to connect everything together. This involves actually soldering 6-conductor cables to a circuit board and/or splicing cables together to provide for an input (from the pedals) and an output (to the T500RS wheel or to a Bodnar cable for stand-alone use).
This was my original concept for the production version:
The problem is that this approach is WAY more labor-intensive than I anticipated -- typically, 5 or 6 solder connections should be no big deal from an assembly standpoint, but the 6-conductor cabling that is used for this type of application isn't really intended for solder-type applications. These cables are typically intended to have connectors crimped onto them, like your typical phone jack or network cable, and the internal wires are fairly delicate, so while you CAN make solder connections with them, they are very fragile once they're soldered in place.
From an assembly standpoint, this fragility makes production dicey, because if the assembly isn't handled
just so while putting the electronics package together, I'm faced with having to repair broken wiring. A little extra care can make this work, but if it's this fragile during assembly, then I'm not comfortable with how durable this would be in actual use over the long-term, especially since this will literally be living "under foot."
This general packaging concept would have kept the production costs fairly low, because all that would be required with the package for the electronics would be a couple of simple access holes that could be easily drilled into the plastic enclosures to allow the cables to exit the package.
The alternative is to move back towards my initial concept, utilizing connectorized cables and a custom electronics package that incorporates the same type of plugs used on the T500RS wheel. This means a custom circuit board will be required, so I can't use existing retail load cell amps from folks like Derek Speare or Leo Bodnar, which drives the price up because a custom circuit board is going to cost ME more up-front, and even in quantities it won't be as cheap as a load cell amp from Derek or Leo would be.
The problem doesn't stop there, though, because the need to use receptacle-type jacks on the electronics package means that the enclosures will have to be custom cut to accommodate the jacks, and this is going to cost more than simply drilling a couple of access holes to feed cables through would cost (think custom CNC cutting for every electronics enclosure). This runs the cost up even further, but as a result, the final version will be more durable and reliable, which is what you're looking for with this kind of thing.
This is what I'm envisioning will be required for the final production version at this point:
I am waiting for a quote to come back on the cost of the custom circuit boards and the custom-cut plastic enclosures, so at this point I have no idea what this is going to do to the overall cost of the mod, but I do know it will be at least slightly higher than my target price point of $100.
So, that's where things stand right now -- this little snag has delayed the build-up and deployment of my pre-production beta test units, but I have figured out how to make the prototypes work using my "low-cost" design, and I can take some extra measures to ensure that those initial units will be durable enough for me to gather some general feedback from my designated testers.
This has delayed deployment of the pre-production prototypes to my beta testers because the initial prototype production run is going to take longer to build-up than I had anticipated, so I've asked them to be patient.
Ultimately, I think the overall quality will be a bit higher in the end, and I'd rather produce a higher-quality item that's appropriately durable, as opposed to producing something a little less pricey that has some dubious issues in terms of build quality.