Rally Controller With Bluetooth
Introduction: Rally Controller With Bluetooth
Do you want to try rally? Are the navigation equipment expensive? Look no further!
Here i will post how you make your own rally navigation controller for bikes.
There is 2 parts you need to make.
1. Handlebar controller
2. Bluetooth unit
This page will be updated with new designs, solutions and code so check in every now and then.
Step 1: Handelbar Controller Parts
Parts list:
3D printed shell.
Model v1.0 https://www.thingiverse.com/thing:4861162
Model v2.0 https://www.thingiverse.com/thing:4890343
Model buttons only https://www.thingiverse.com/thing:4890338
MCS18 Push Button IP65 round 18mm 48Vdc/125mA, part no: 1241.1104.7097
Gasket for MCS18 to IP65, part no: 0098.9201
Honeywell 1MT1-7 - Toggle switch (ON)-OFF-(ON) 1CO IP67/IP68, part no: 1MT1-7
RND Signal cabel 205-01148 - M8 connections, 2 m, 6 Pole, A-code, RND Connect, part no: RND 205-01148
M5 nuts
M5 bolts
O-ring outer diameter 13mm and rubber diameter 1,5mm
Tools:
Solder iron
Cutters
Small phillips screw driver
Super glue
Small wrench
Note: To make the unit cheaper you can change the RND Signal cabel and contact on the controller and Bluetooth unit, for a normal 6 pole wire, it will save you around 25-30€.
Step 2: Handelbar Controller Assemble
Print your shell.
I like to use PLA or PLA+ with a 50% infill and supports for the printing bed.
Clean the part from the support
Cut and glue 3mm (2,85mm) filament in to the shell as alignment pins.
Glue the M5 nuts in place.
Mount the MCS18 buttons with the gasket, and/or the toggle switch
Cut the 6 Pol signal cable to the length you want and thread it through the upper hole.
Run the GND (black cable) to all the buttons and or toggle switch and soder it in place.
The cabels have these functions:
Black - GND
Brown - Tripp down
Pink - Tripp up
Grey - Roadbook FW
White - Roadbook - BW
Blue - Play/Paus
Soder the cabel to the switch function you want to have, most Roadbook apps have the function to change the buttons.
Glue the shell parts together use rubber bands and or spring clamps to make a tight fit.
If you have gaps use more super glue or plastic putty to seal the model.
Step 3: Bluetooth Units
Here you have two options, one with a premade Bluetooth sender and a one ESP32 you program yourself.
Premade Bluetooth puck.
Pros:
No programming
Battery powered
Easy to change battery
Small
Cons:
Hard to soder
Might need to edit the 3D model
ESP32
Pros:
Easy to soder
Can be USB and battery powerd
Can update the software
Cons:
Needs to be program
Gets big with a battery
Needs expensive special battery
Step 4: Premade Bluetooth Unit
Parts:
3D printed case https://www.thingiverse.com/thing:4890354
Bluetooth unit.
Sensor cabel, 6 Pole, M8, RND Connect part number: RND 205-01122.
Rubber O-ring 45 mm outer diameter and 3.3 mm diameter on the rubber.
M5 nuts
M5 screws 22 mm
Tools:
Solder iron
Cutters
Small phillips screwdriver
Small wrench
Superglue
5mm drill
Connect the unit to your device.
Print the case, check if the mounting hole is the right size.
Different brand have slightly different sizes +- 1 mm
If not, edit the model and reprint.
Drill out the holes with a 5mm drill.
Glue the M5 nuts in place.
Mount the sensor cabel in the 3D printed case.
Push the nut from the sensor cable in the groves in the case and screw the cable in place.
Be carefully when sobering, the board its sensitive to overheating and will destroy the unit.
Open the unit and remove the button front to expose the board and reinstall the case. 16