Sim Racing Handbrake (USB)

It was Christmas and I looked for a handbrake for my nephew. This is a remix of yamaha26's version, the best 3D printed handbrake that I found. It looks and works very well!

This project uses my old wired mouse, which was the main reason why I remixed the original one. I discovered that the mouse is still available in stores. If you don't have one, you should buy it instead of wasting time creating another remix (like I did). The new mouse costs 125CZK, so it's definitely the cheapest way. Of course, if you want, you can also do a remix (YES, I attached the STEP file) and use different PCB from mouse or Arduino with ATmega32U4 + Microswitch + Micro USB cable.

List of Changes

• Mount for Genius DX-120
• Durable lever (M8 Threaded Rod)
• Add thread for screw that holds the lever
• Change output of USB cable
• Add holder for cable tie zip for securing USB cable
• Larger tolerances for M8 screws/nuts

Bill of Materials (BOM)

• 1x USB computer mouse Genius DX-120 - disassemble and use board only (PCB)
• 1x M8x150 mm Threaded Rod
• 3x M8 Nut (DIN 934)
• 1x M8x55 mm Screw (DIN 931)
• 1x M8 O-ring - for silence, under head of screw (DIN 931)
• 1x M8x70 mm Screw (DIN 931) - cut the head and create slot for screwdriver
• 1x M8x30 mm Screw (DIN 912)
• 2x M2.5x5.5 mm Screw (DIN 965) - drill/enlarge the hole(s) in PCB, only one on the upper right side can be used
• 1x Small Spring (from PEN)
• 1x Big Spring ID 10 x 30 mm
• 1x 8.4 Washer (DIN 125A) - at end of the bigger spring, under mouse PCB
• 1x Plastic Cable Tie ZIP 2,5×100 mm

Print Settings

• Here are only changed parts (*.stl files)
• You have to print the missing parts from the original design
• Slicing: 15% Adaptive Cubic Infill, 2 perimeters, 0.25mm layer height (less printing time)

Build Process

1. Print the parts and use Tap & Die Set on all M8 threads (3x)
2. Cut the M8 threaded rod (optional, you can also use the original, printed lever only)
3. Cut the head of the longest M8 screw (optional, you can use any M8 screw with thread, but it's better to use one without thread in the section where the lever moves)
4. Screw the PCB onto the main body (Haz)
5. Assemble the lever with the small spring (Lever + Csuklo)
6. Screw the last M8 screw with the big spring onto the lever part (Csuklo)
7. Secure the USB cable
8. Attach the missing covers (Burkolat)
9. Move on to the Software section
10. Enjoy ;)

Software (X-Mouse Button Control)

• You have to tell to computer: Right mouse button click is the same as keystroke “h”
• Download and run the utility
• Example Setup: 
  1. Tab: Application / Window Profiles => Add
  2. Find: Dirt Rally 2.0
  3. Tab: Layer 1 => Right Button => Simulated Keys
  4. Enter the custom key(s) => h
  5. How to send the simulated key strokes => 3 During (press on down, release on up)
  6. OK => Apply
  7. Run Dirt Rally 2.0 => Options & Extras => Input => Keyboard => Handbrake => Remap Binding => Use 3D printed handbrake => "h" should appears