Formula Force EX Teardown & Button Box Mockup

I took apart my old Logitech Formula Force EX a couple of days ago. In search of using the buttons housed within it. Apart from the two I will put onto the wheel, I will need additional buttons and this seemed like an ideal way to get them.

Steve Jones – the guy who designed and made the Cockpit I am trying to re-create used Plastic boxes, and the buttons from a Belkin Nostromo. Using purchased wire and new red push buttons. While these look fantastic, I’m not sure if I’d be able to do that. I’ve no idea how he connected it all and got it working.

So…I pulled apart the FFEX. The PCB is quite simple and it was obvious which push connectors did what. I removed the one for power knowing that wouldn’t be needed, I removed the connection for the pedals and the other for the Force Motor. There were two remaining pushfit connectors – one for the USB and the other for the 12 buttons on the wheel.

After figuring this out, I pulled off the front of the wheel, exposing 3 PCB’s for each set of 4 buttons. I was left with the main PCB, 3 button PCB’s and the usb cable. I tested it in game, and it all worked.

The one issue that remains is the length of the connectors between the 3 button PCB’s. Its fairly tight and not very long either. I wanted to mount it on the inside facing vertical as Steve had done. However, using these buttons in this way it wouldn’t be possible. The smallest configuration I can achieve is to have 4 at the top and then two sets of 4 next to each other below. Creating a box around 12cm high and 8cm wide. Roughly.

This is going to be a bit of a bodge job, but it should work well. I cut the front of the wheel apart, so the 3 PCB’s are no longer joined by the plastic. I will however be leaving on the plastic front, as it contains the button pots/springs.

These plastic fronts will be glued onto the rear side of an aluminium plate. With the holes cut through the aluminium for the buttons. I purchased some bolts, identical in diameter to the existing buttons. I will cut these to size – Enough to stick out, go through the aluminium and press on the rubber to action the click.

I hope to punch in the button names with a punch (obviously). And then fill them with yellow.

These will be glued directly to the rubber. If all goes well it should end up looking something like the mockup I’ve attached to this post.

Fingers crossed!