how to build a FFB direct drive STEERING WHEEL from a HOVERBOARD | step by step

Summary

This video demonstrates how to transform a €20 hoverboard into a high-performance 15 Nm direct drive steering wheel for racing simulators, costing around €200. The creator meticulously disassembles the hoverboard motor, modifies the stator and rotor, and integrates a custom PCB and 3D-printed parts. The MKS X Drive Mini controller, magnetic encoder, and adjustable mounting system are installed to create a smooth, precise, and robust wheelbase. The result is a cost-effective, premium-feeling steering wheel that outperforms many entry-level commercial options. The video also highlights PCBWay for custom parts, practical assembly tips, and troubleshooting for firmware upload, ensuring a successful build.

Takeaways

• 🛹 The project demonstrates converting a €20 hoverboard into a premium direct drive steering wheel with 15 Nm torque.
• 🔧 The build starts by disassembling the hoverboard, removing the motor, and preparing it for modification.
• 🛠 Modifications include drilling holes in the stator and rotor to route cables and install a steel rod for motor rotation transfer.
• ⚡ Motor sensors that are not needed are removed, and phase wires are rerouted through the motor shaft.
• 🧩 A standard six-bolt pattern and a wheel spacer are added to the rotor to mount the steering wheel securely.
• 💻 PCBWay provides custom PCBs and 3D printed parts, offering low-cost, high-quality manufacturing services for the build.
• 🔌 The MKS X Drive mini controller is used, including adding a brake resistor, USB connection, and proper soldering of power and encoder cables.
• 🧲 The encoder mounting system involves bearings, a 3D printed adapter, and precise placement of the motor spoke for accurate feedback.
• 🖥 The wheelbase body is assembled with 3D printed parts and secured to the controller and table, with adjustable mounting using steel tubes.
• ⚡ Power supply setup includes a 24V, 10A unit connected via XT60 connectors, mounted under the desk for stability and accessibility.
• 💾 Firmware installation may require clearing the board memory using the boot button if the PC does not recognize the wheel initially.
• 🎮 The finished steering wheel is more precise, smoother, has less friction, feels robust, and is cheaper than many entry-level non-direct drive wheels.
• 📱 Viewers are encouraged to follow the creator’s Instagram and subscribe to keep updated on future builds and projects.

Q & A

What is the main goal of the project described in the video?

The goal is to convert a standard hoverboard motor into a premium direct drive steering wheel with 15 Nm torque for a racing simulator setup.

What is the approximate total cost of the parts required for this build?

The total cost ranges between €100 and €200, depending on the parts chosen.

Which open-source project does this wheel build follow?

The build follows the open-source FF (Force Feedback) project, which provides guidelines and design resources for DIY direct drive wheels.

What modifications are made to the hoverboard motor's stator?

The stator cables are routed through the shaft, a 3 mm hole is drilled for a steel rod to transmit rotation to the encoder, and the motor hall sensors are removed.

How is the rotor modified for this project?

A 2 mm hole is drilled through the rotor center to thread a standard bike spoke using a Pok nipple as a secure nut, and a six-bolt pattern is drilled to mount the steering wheel spacer.

What role does PCBWay play in this build?

PCBWay provides the custom PCB and all necessary 3D printed parts, offering low-cost, high-quality on-demand manufacturing services.

Which controller is used in this project and why?

The MKS X Drive Mini controller is used because it supports brake resistors, USB connectivity, and integrates well with the custom PCB and motor for direct drive functionality.

How is the magnetic encoder installed and connected?

The encoder is mounted using a bearing and a 3D printed adapter, with the magnet placed in the appropriate hole. It is connected to the PCB with a five-pin connector following specific color-coded wiring.

How is the wheelbase mounted to a desk?

The wheelbase is attached to a 10 mm plywood sheet with six wood screws and washers, which is then mounted under the desk for a secure and adjustable setup.

What steps are taken to ensure the power supply works correctly?

A 24V, 10A power supply is mounted beside the wheelbase, connected with an XT60 connector and wire harness, and properly drilled and fixed under the desk to provide stable power.

What troubleshooting step was necessary during firmware installation?

The board initially was not recognized by the PC, so it had to be powered on while pressing the boot button to clear memory in the SD Cube programmer before uploading the firmware successfully.

How does the final build compare to other entry-level steering wheels?

The final build is smoother, more precise, has less friction, feels more robust, and is cheaper than most entry-level non-direct drive steering wheels on the market.