I am currently taking a CNC class and decided to do the Tiller and Rudder Pedals using aluminum plate instead of 3D printed parts wherever I can. On the Tiller the only 3D printed part is the Tiller itself. It would be too expensive to CNC. I did all of the CAD work and CAM work in Solidworks, and converted all of the metric hardware to inch. Yep, you guessed it, I line in the US. It was mostly painless to bring in the Fusion files. All of the CAD and CAM work is done for the tiller, and I just started machining the parts. Hopefully I will have the parts done within a week or so. One nice thing is it will be easy to make changes and modifications. I am looking at using compression springs in place of the normal springs, but this is still a work in progress. Below are some of the parts I did on a HAAS Vertical Mill. I still need to face the back of the parts and they will be ready to go. I will continue to post as I get more of the work done. I have also designed a desk mount for the tiller.
I have most of the CAD work done for the Rudder Pedals. The only thing that will be 3D printed are the Pedals. Again, too expensive to do in aluminum. I am also going to directly connect the Hall sensors to the Sync Lever and Brake pedal stems so I don't have to CNC the gears. It is doable just a royal pain in the tail end. I am working on a way to use compression springs on this build also. The brakes should be easy, not too sure about the Sync lever. We shall see. I will post in the rudder section as I get closer.