Full Project Log on the RPF

My posts copied here.

Okay, so I went a bit overboard on this one. (as always) Currently I want to make this for myself and release the design files once done. (If you want me to start a separate thread let me know)

I took yourgeneral dimensions to start from, but then redid the whole model based on the side image and the ball size you selected. I ended up with a radius of 1.41" and a housing width of 1.66". The shaft is about 3/8" too long, but if you cut that off the threaded end the left over threads will be screen accurate).

I integrated the baseplate into the housing since it looks like there is a weld or casting line on the actual prop. For the corner screws I made them #8-32 tap holes, so you can drive in screws to complete the look even if you use the magnets. The corner screws are not symmetrical on the actual prop, but I couldn't bring myself to place them off center.

To get around the screw self-loosening issue I put the screw threads into the housing, with a clearance hole on the shaft holder.

I added the ball spring, with detents at both extremes and 90 degrees.

I wanted a way to be able to use this to connect to some electronics, it would make an awesome throttle for my Star Wars Squadrons VR rig. So I added a gear to drive a thin potentiometer. Then I realized that to make it feel realistic it needs some smooth friction, so I added a speed limiter on another gear. All this will make the inside look extremely technical and of course and add to the effect.

Too bad that Zenix's replica knob is threaded for M16x1.5mm and McMaster doesn't' carry anything with that thread, I may have to see what I can get on eBay, or make my own ball as you did.