Small update on the TWCS modular rebuild project.

This phase has mostly been focused on refining the housing design, correcting measurements, and testing the internal layout before committing to final prints.

Recent progress

• Ordered a better soldering iron + heat gun to improve wiring and finishing work
• Received the printed Walls MK - II parts
• Used a rotary tool/drill to manually correct fitting and measurement issues after test assembly
• Updated the Fusion design based on the real-world fitting problems
  • Current revision:
    • Main Side Wall MK - III
• Started a cardboard prototype for the rear wall to test:
  • cable routing
  • connector spacing
  • internal clearance

Pic 1 – Printed side walls

• Latest printed revision for the housing expansion

Pic 2 – Cardboard prototype with side wall installed

• Testing fitment, spacing, and overall structure before committing to more prints

Current focus

Trying to balance:

• modularity
• internal space
• structural rigidity
• smooth slider movement

without making the housing oversized or difficult to maintain.

Biggest lesson so far

Even when measurements look correct in Fusion, real-world tolerances and assembly clearance still force adjustments after printing.

The cardboard prototypes are helping a lot before committing to more prints.

Next steps

• Finish rear wall prototype
• Finalize connector placement
• Start planning internal mounting positions for STM32 + wiring
• Make the grip modular to simplify future upgrades and modifications

Working on turning a non-working TWCS throttle into a modular setup using an STM32 (Blue Pill) + hall sensor.

Here’s where I’m at right now👇

Current progress (see photos)

Pic 1/2 – GX12 power connector (build)

• Started wiring a GX12 4-pin for power/USB
• Mapping:
  • Red → VCC
  • White → D-
  • Green → D+
  • Black → GND
• Added sleeve + strain relief

Pic 3 – Slider upgrade

• Custom 3D printed carriage (Ordered Online)
• Much smoother than stock so far

Pic 4 – Walls prototype

• Early structure tests for expanding the housing
• Trying to add ~2 cm space without affecting movement

Pic 5 – Cardboard housing (electronics)

• Used to leave original housing free to "upgrade."
• First mockup to test internal layout
• Helps visualize cable routing and spacing

Pic 6 –Full cardboard prototype (working)

• Breadboard setup with all original buttons working
• Validating full system before committing to final design

What I’ve done so far (short version)

• Replaced throttle axis with hall sensor (AS5600)
• Flashed STM32 + configured in FreeJoyQt
• Mapped original grip PCB wiring
• Rebuilt rails + prototype housing (cardboard → printed parts)
• Started working on modular connections (GX12 / GX16)

Current focus

• Expanding housing (~+2 cm) to fit everything internally
• Designing a proper connector mount on the slider
• Cleaning up wiring layout

Challenges

• Hall sensor alignment still needs fine-tuning
• Keeping everything modular without overcomplicating it
• Making sure nothing interferes with slider movement

Next steps

• Place all GX16 connections
• Move electronics inside the housing
• Finalize connector mounting
• Lock down internal layout
• Preparation to make the grip replaceable

If anyone has experience with:

• TWCS mods
• Hall sensor alignment
• Modular HOTAS setups

I’d appreciate any input.

More updates coming as I refine this.