Re-worked my flight controls yesterday and though it hasn't improved my on-line performance, the stick has a nice feel to it. Gimbals are made from tilting plywood platforms, pivoting on home-made hinges. Lengths of bungee cord give some centering force. The electronic guts consist of the Bodnar BU086 board, sensors are Hall effect for roll and yaw, pots for throttle. First version of the stick had simple switches on top for pitch trim and guns. New version uses a spliced-on Saitek stick grip for the grip. I'm using the hat switch for roll trim and pitch trim, two buttons for guns, one button for TeamSqueak. Two throttles for now, though I just use one for IL-2. The helo collective, when needed, is plugged into output from throttle #2. Yes, I do fly FS9 occasionally, though it's a secret; hey we're all friends here, right?
It was fun to build this rig, still not ideal but a step up from the two commercial joysticks I've used. Really happy with the Hall Effect sensors and the ten-bit ADC Bodnar board , too. When I do a joystick calibration, I can see reproducible signal change from about 1/8 inch stick travel. That translates to about 1/3 of a degree stick deflection.