DIY Hall Effect Sim Handbrake Project

In this video, I complete my DIY sim racing setup by building a custom handbrake to complement the pedals and steering wheel I previously designed. Inspired by outrageously priced commercial handbrakes—often little more than glorified switches—I set out to create an affordable, high-quality alternative.

The handbrake integrates seamlessly with my existing pedal controller, allowing for standalone operation independent of other peripherals. For those using pre-built solutions like Logitech steering wheels and pedals, this handbrake can still enhance your sim setup.

Design Overview:

• Structure: Based on my earlier pedal design, with modifications to replace the pedal mechanism with a handbrake lever.
• Material: 3D-printed components, including a reinforced hollow shaft to accommodate an 8mm threaded rod for added strength.
• Controller Integration: A compact enclosure for the controller ensures easy connection and independent functionality.

Challenges and Improvements:

During initial testing, the handbrake snapped under pressure due to insufficient infill in the 3D-printed parts. I reprinted the components at 100% infill, significantly enhancing their strength. The threaded rod was extended fully through the shaft, providing additional durability.

Assembly and Testing:

• After painting and assembling the parts, I connected the controller and sensor. Initial adjustments ensured proper alignment and sensitivity of the hall-effect sensor.
• Once calibrated, the handbrake worked seamlessly with the PC, offering precise input recognition.

Key Takeaways:

• Strength Optimization: Using 100% infill on critical parts ensures durability without compromising functionality.
• Customization: Designed to be user-friendly and adaptable, making it a great DIY project for sim racing enthusiasts.

Watch the video for a step-by-step guide on creating your own DIY handbrake, and take your sim racing experience to the next level!

If you would like files to make this handbrake and pedals, you can get them by clicking on the image below.