My ZF Auto - Paddle Shifter Idea

[Gothefalcon]

Forgot to say also... The Taurus paddles are +/- on both sides of the wheel.
Push away with your thumb (either side) and it downshifts... pull towards you with your fingers, and it upshifts. Doesn't matter where the wheel is rotated when you need to do it... no confusion ! (very good for an old bloke like me )

I have also added a feature where if you flick + and - paddles at the same time... it put's the box back into Sports Auto. So... you have manual and sports auto on demand, at the wheel (on mine, the auto stick must be in sports auto position for the system to operate)

D

[JasonACT]

Originally Posted by Gothefalcon

Hope that made sense !??

D

Yes! Thanks for that, I hadn't realised until I saw where the issue was in your new photos. I'll no doubt have to be creative to avoid that bend in the stalk.

The +/- thing might explain the other photos of the Mazda steering wheels too - both sides said "DOWN" which I just didn't get until you mentioned that! Thanks again

I hadn't considered going back into sports automatic mode as a function either, that's nice. I don't think my "solution" can do that, I'm piggybacking on the shifter's socket where you have it going through your device. If only I had an endless supply of those sockets and plugs!

Again, nice work and thanks for all the hints!

[Gothefalcon]

Originally Posted by JasonACT

might explain the other photos of the Mazda steering wheels too - both sides said "DOWN" !

That's just to remind you, you have to drop into Coles on the way home, to get milk !

D

[JasonACT]

This looks like it might work...

I 3D printed a probe device for my CNC machine I built a few years ago (it doesn't get enough use) and ran it over my spare FG leather steering wheel's top arm. I used blue painter's tape to cover the perforations in the leather:



This produced a surface I can use in designing objects in OpenScad, which is what I use to make 3D things to print with my 3D printer:



So, I went about designing a simple paddle I could house a mini-switch in:



And subtracted away the back of the paddle with the scanned surface:



Printed it for testing using silver PLA plastic (it needs to be printed in ABS plastic later so it can withstand the temperatures in a hot car - my last job had gold plastic loaded, and I didn't bother cleaning it before doing this test job):





Stuck the switch in:





Tested out the screws and bolts I intend to use:



Double sided taped it to my spare steering wheel:











Seems to fit well (it should with that scan I did on the CNC machine).

Time to try it in the car with the double sided tape:





One important test needs to be done - and it passes!



Not the worst looking thing either (or am I being biased?):

[JasonACT]

Had an epiphany, double sided tape would allow the makeshift copper "needle" of my probe "grab" much better and give a cleaner result...



I know, right...



Yes, a steering wheel fits in my beast...



Damn it, the needle found its way into 2 leather perforations! (left=old scan from the other day, right=new)



Nothing a quick text-edit doesn't fix though:



The new surface of the button:



Printed in ABS plastic, at twice the detail and half the speed, alongside the test-prototype:





scan6.scad file contents (for anyone else who wants to make one)


// Defaults for curved surfaces
$fa=0.5; // default minimum facet angle is now 0.5
$fs=0.5; // default minimum facet size is now 0.5 mm

module screw() {
cylinder(r=3.5/2,h=11.8);
cylinder(r1=6/2,r2=3.5/2,h=2);
translate([0,0,-2]) cylinder(r=6/2,h=2);
}

module button() {
cube([15,6,4]);
translate([15/2,6/2,0]) cylinder(r=3.5/2,h=4.4);
}

module paddle() {
difference () {
translate([11,7,3.2]) rotate([-4,3,-2]) minkowski()
{
union () {
translate([0,0,0]) rotate([0,4,0]) cube([20,20,3.5]);
translate([20,0,-1.4]) rotate([0,-3,0]) cube([20,20,3.5]);
translate([30,0,-3]) rotate([0,-15,0]) cube([25,20,3.5]);
}
sphere(r=3);
}

mirror([1,0,0]) translate([-1,0,63-54-2.4]) rotate([45,0,90]) surface (file="scan6.txt");

rotate([-2.7,0,0]) translate([15+45,12.5,6]) rotate([0,179,0]) button();
translate([17,10.5,8]) rotate([4,205,0]) screw();
translate([17.25,24,7]) rotate([4,205,0]) screw();
translate([10,16,-1]) rotate([0,0,-2]) cube([40,2,5]);
}
}

translate([0,0,30.1]) rotate([4-90,1.8,2]) paddle();


scan6.txt file contents (probe height values):

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[JasonACT]

Apparently "for sale" items on the forum here expire after two months?

http://wwww.fordforums.com.au/showth...09#post6312909

Still shows up as a thread, but it's no longer listed in the index:

http://wwww.fordforums.com.au/forumdisplay.php?f=42

Anyway, I'm enhancing the program (firmware) on these devices so it will detect an extra 1K ohm resistor in series on the cruise control wires/buttons, which are the same on the BF and FG (it doesn't matter which of the two wires is used to insert the new resistor, either one will work, it's all the same) which will allow 2 extra buttons to be used. On a BF steering wheel (of which I don't have one to scan with my CNC machine - though I'm open to doing it if one shows up in Canberra for me to do so) it needs a 2nd 1K ohm resistor on the radio button wires too.

When my device boots, it waits until all cruise buttons are released and tests if the extra resistor is present (usually it will boot when the car is unlocked, so no-one would be holding down a button, but I figure this is safest). If it is present, it configures the two extra buttons for use - which operate by a total-short on the two sets of wires. The cruise On/Off button was normally a total-short on the right hand side wires, but is now remapped to be 1K ohm higher. FG radio buttons never had a total-short button, the device detects the extra function without any change. BF radio buttons has the Volume Down button as a total-short, but with the extra resistor inserted, it is now remapped too.

These additional paddles can now be added in while leaving all the normal steering wheel buttons to operate as they did originally. Note though, the paddle shift up/down takes priority over all other buttons (as before, you can't use two buttons on the same side of the steering wheel at the same time).

I'm not inclined to add a new for sale post, I've only today added this extra logic to the device and I had actually tested out the original one for quite some time before I first mentioned it here. For the time being, it's probably better for me to hold on to the three I have so things don't become complicated.

[burkey05]

will these also suit BA/BF/Terry steering wheels?

can they be added to your existing paddle shift setup?

[JasonACT]

The contact-part of the switches I'm using in the 3D printed paddles are really small (only 0.7mm):

https://www.jaycar.com.au/0-7mm-spst...witch/p/SP0600

So these paddles need to be designed to "perfectly" fit the steering wheel's contour - so nothing gets in the way and the switch is pressed reliably.

I have not seen a BA/BF steering wheel in person (or an older Territory for that matter, though I'm sure the SZ has the same steering wheel as mine). I'm sure the older ones are different enough to the FG though for them to not work properly right now. I would need a BA/BF steering wheel to scan on my CNC machine and some extra time to align it properly on my 3D paddle model for it to work I think.

Then test that the washer/headlight stalks don't hit it! I'm also unsure if the plastic vs leather steering wheels have vastly different dimensions, but I assume they will be close enough.

My plan is for this to work on the existing device, but you will need to return (just) the circuit board (leave the wiring in place) to me for a firmware update. I've got a new firmware, but it needs thorough testing. I'll be installing it on my car tonight, and driving around for a while in the current mode (to make sure it doesn't try to enter the new mode in error). At the moment, the thing is only bench tested (but it is working reliably on the bench).

Then the only extra things that need to be done to "upgrade" is to pull the steering wheel off, solder two resistors (only one for the FG) to the button wires under the air-bag and bolt the 2 paddles on the plastic cowl at the back of the steering wheel. The device will automatically switch to the new mode next time it boots.

Sheesh, sorry for the long reply to a simple question!

[burkey05]

I can possibly get you a BA/BF/Terry steering wheel, I just need to check if the "chunky" steering wheel is the same as the standard on the backside(I've got a chunky wheel).

Originally Posted by JasonACT

I'm piggybacking on the shifter's socket where you have it going through your device. If only I had an endless supply of those sockets and plugs!

Again, nice work and thanks for all the hints!

what sockets and plugs did you need? the ones for the sports shift? I can get them fairly easily

[JasonACT]

I did an Internet search for images, and I can see there are big differences with the fully plastic BF steering wheels to what I have. There's no thin plastic cowl at the back - it's solid plastic throughout. That might take some extra drilling to make holes, and possibly different (self tapping) screws? I'm also using the fact that it's thin plastic on mine for the "flex" of the button to work without pressing too hard.

This is all being made up as I go! It should be easy to change the paddle design to include a flexy pattern just past the screw holes though

Anyway, I'm happy to stick whatever steering wheel I can get my hands on in the CNC machine and publish the results here. Let me know what you find burkey05, thanks!

RE: the sockets and plugs, yes the sports shift.. but the circuit boards are made up now, so there's not much chance of changing the design to include the extra function to return to sports automatic mode. Thanks though (Also, the FG seems to have more pins populated than the BF - which might also be a problem?)

[burkey05]

I'll see what I can find at the wreckers tomorrow

The sockets(2 x male & 1 x female) just make it more plug and play if nothing else

[JasonACT]

Looks like I'm the proud owner of this for $25 - I'll pick it up tonight or tomorrow:

https://www.ebay.com.au/itm/Ford-BA-...53.m2749.l2649

[JasonACT]

Picked it up this arvo...



FG vs BF:



Recently bought some really nice silver PLA plastic (no good for the car, but looks great for the prototype):





Oops, dented my button pushing it in...















scan7.scad


// Defaults for curved surfaces
$fa=0.5; // default minimum facet angle is now 0.5
$fs=0.5; // default minimum facet size is now 0.5 mm

module screw() {
cylinder(r=3.5/2,h=11.8);
cylinder(r1=6/2,r2=3.5/2,h=2);
translate([0,0,-2]) cylinder(r=6/2,h=2);
}

module button() {
cube([15,6,4]);
translate([15/2,6/2,0]) cylinder(r=3.5/2,h=4.4);
}

module paddle() {
difference () {
translate([11,7,3.2]) rotate([-4,3,-2]) minkowski()
{
union () {
translate([0,0,0]) rotate([0,4,0]) cube([20,20,3.5]);
translate([20,0,-1.4]) rotate([0,-3,0]) cube([20,20,3.5]);
translate([30,0,-3]) rotate([0,-15,0]) cube([25,20,3.5]);
}
sphere(r=3);
}

mirror([1,0,0]) translate([9,0,-5]) rotate([45,-6,90+2]) surface (file="scan7.txt");

#rotate([-2.7,0,0]) translate([15+45,12.5,6]) rotate([0,179,0]) button();
translate([17,10.5,8]) rotate([4,205,0]) screw();
translate([17.25,24,7]) rotate([4,205,0]) screw();
translate([10,16,-1]) rotate([0,0,-2]) cube([40,2,5]);
}
}

translate([0,0,30.1]) rotate([4-90,1.8,2]) paddle();


scan7.txt

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[JasonACT]

Originally Posted by burkey05

I'll see what I can find at the wreckers tomorrow

The sockets(2 x male & 1 x female) just make it more plug and play if nothing else

I don't know if they are all the same, but the scan above might work well on all BF steering wheels. Just need to add some small washers between the wheel and the paddle so it can flex a little I think. The wheel I got seems to be some sort of soft rubber, so that should work well.

I agree with you too, it would be nice to make it more plug and play with proper plugs and sockets, but to get to the FG ones, you pretty much need to dismantle the entire centre console. I can't believe Ford did that - to be quite honest. Until FGs are older and people are not so worried about resale value, I'm not sure it's worth it - and it would upset me to ruin good spare parts to get just those bits... Even though I quite like yours

[burkey05]

I could just get to the plug with a flat head screw driver and some fiddling. Didn't have to remove the shifter or anything. Not sure how hard FG's are tho.

I'll have a look tomorrow if the wheels are different in shape at the back, I wouldn't think so tho

[JasonACT]

The new firmware was installed in my car and everything continued to work as it did before. There was no big worry there, an extra 1K resistor is easily distinguished by the micro-controller I'm using. So today I upgraded things to test out the new mode:

Thin wire lengths for the buttons, I went for about 18cm, but from the photos later, they could be shorter and still work. Also shown, some pins I'm going to solder on once the wires are passed through the hole I'm going to make:



Drilled the holes, made mistakes, drilled more, buttons fitted:



Looks ok:



Good fit:



Don't tighten too much though!



New buttons printed (new ABS+ plastic which doesn't warp as much, they say, seems to be ok):



More parts to make it nice:



Solder in the wires:



Solder in the resistor on the cruise control buttons plug wire:



Heat shrink:



On the FG, just need to solder in the extra radio controls plug, a 2nd resistor is not needed:



Buttons in, on wheel, ready to plug in the paddles:



Plugged in and tidied up - could have used a few less centimetres of wire:



Steering wheel back on the car:



Left side:



Right side (this cowl is from the spare steering wheel I bought on ebay, and I just realised it's got chipped off bit of plastic in this picture):



No big deal, I've still got my original one sitting in storage now.

So took it for a test drive.. Had to wait for it to warm up before it would let me select sports shift (I knew there was a delay from testing before, but it seemed to take an age!). Finally, entered sports mode and right away, pressed the cruise control button to change gears!

Needless to say, this continued until I got home throughout my test drive.

When I realised each time, the paddles did work like they should. And yes, I was able to engage cruise control while driving with the paddle shifters.

Things to note: It's hard to get the screw pressures all the same, so both paddles feel the same. Looser seems to work better, but liquid thread-lock is needed then.

Is it better? Not sure. Certainly, the paddles are in a better position when I'm holding the steering wheel by the upper arms. I think it'll just take me a while to get used to it (much like it did with the mode/cruise version).

I also cleaned up the OpenScad files of the FG and BF (the scan txt files have not changed). I was printing them upside down, but with the cleaned up versions it is pretty easy to print them in whatever orientation you want. (I.E. The weird rotations from the originals have been removed - that was experimenting at its best!)

FG


// Defaults for curved surfaces
$fa=0.5; // default minimum facet angle is now 0.5
$fs=0.5; // default minimum facet size is now 0.5 mm

module screw() {
cylinder(r=3.5/2,h=11.8);
cylinder(r1=6/2,r2=3.5/2,h=2);
translate([0,0,-2]) cylinder(r=6/2,h=2);
}

module button() {
cube([15,6,4]);
translate([15/2,6/2,0]) cylinder(r=3.5/2,h=4.4);
}

module paddle2() {
difference () {
translate([10,7.7,3]) mirror([0,1,0]) rotate([0,0,1.5]) minkowski() {
union () {
translate([1,0,0]) rotate([0,0,4]) cube([20,3.5,20]);
translate([20,1.4,0]) rotate([0,0,-3]) cube([20,3.5,20]);
translate([39.99,0.35,0]) rotate([0,0,-15]) cube([14.6,3.5,20]);
}
sphere(r=3);
}

mirror([0,1,0]) translate([0.8,-6.5,30.53]) rotate([-2,0,0]) rotate([0,87.3,223]) surface (file="scan6.txt");

translate([44.15,7.65,10.35]) rotate([91,2,3]) button();
translate([16.3,9.3,19.7]) rotate([89,0,-23]) screw();
translate([16.2,9.2,6.1]) rotate([89,0,-23]) screw();
translate([9.3,5.5,12.15]) rotate([94,-0.2,2]) cube([40,2,5]);
}
}

mirror([0,0,1]) translate([0,0,-26]) paddle2();


BF


// Defaults for curved surfaces
$fa=0.5; // default minimum facet angle is now 0.5
$fs=0.5; // default minimum facet size is now 0.5 mm

module screw() {
cylinder(r=3.5/2,h=11.8);
cylinder(r1=6/2,r2=3.5/2,h=2);
translate([0,0,-2]) cylinder(r=6/2,h=2);
}

module button() {
cube([15,6,4]);
translate([15/2,6/2,0]) cylinder(r=3.5/2,h=4.4);
}

module paddle2() {
difference () {
translate([10,7.7,3]) mirror([0,1,0]) rotate([0,0,1.5]) minkowski() {
union () {
translate([1,0,0]) rotate([0,0,4]) cube([20,3.5,20]);
translate([20,1.4,0]) rotate([0,0,-3]) cube([20,3.5,20]);
translate([39.99,0.35,0]) rotate([0,0,-15]) cube([14.6,3.5,20]);
}
sphere(r=3);
}

mirror([0,1,0]) translate([-9,5.5,30]) rotate([-10,0,0]) rotate([0,90,223]) surface (file="scan7.txt");

translate([44.15,7.65,10.35]) rotate([91,2,3]) button();
translate([16.3,9.3,19.7]) rotate([89,0,-23]) screw();
translate([16.2,9.2,6.1]) rotate([89,0,-23]) screw();
translate([9.3,5.5,12.15]) rotate([94,-0.2,2]) cube([40,2,5]);
}
}

mirror([0,0,1]) translate([0,0,-26]) paddle2();

[moey747]

Hi there, any chance you have made any updates or revisions?

This implementation is interesting:

https://youtu.be/yQwMpQejYZU

[JasonACT]

As documented here, these were the last things I ever did with it (I use it most days though, and I'm quite happy with how it works). I've also run out of components to build them, a guy with 2 BFs bought my last assembled one a couple of months ago - and I had to go to Jaycar to make up a 2nd one that he wanted. They are more expensive to make that way, so I'm afraid that's it - all gone now.