My second take on modding the famous mini remote. First one was similar but much larger as it uses the AA batteries like the original. The aim of this mod was to make it as small as possible but still have it in the thumb driven configuration. And this one really came out small - there’s not much room to spare inside the case.
Be aware that this is basically a prototype, modify your remote at your own risk.
I designed this to be printed in translucent filament in order to have all the LEDs a chance to shine through the case. You might have a bad time seeing any of the indicator lights using e.g. black filament.
Instructions:
Print the parts and see if they fit properly. Prepare to do some sanding, filing and drilling to open all screw holes etc.
Prepare the electronics. This is very nicely explained in the Avio Mini Remote Mod post so I won’t explain it here again: The Avio Mini Remote Mod.
Just note that there is a bit less room in this mod so be careful about the wire lenghts etc.
Screw the potentiometer mount onto the “case_left” using screws from the donor remote.
Hot glue the remote PCB onto the case as well. Might be better to test that all electronics work before using too much glue.
Here’s how mine looked like at this point (the step down converter in under the red heat shrink):
You can see that the battery indicator is attached with a 3D printed part & a screw but additionally I placed some hot glue to secure it firmly. Please use some insulator material (e.g. fishpaper) between the charging board and the remote PCB. I hot glued everything together.
Place the throttle wheel and the spring mechanism on to the potentiometer mount.
Unfortunately I only have a cad picture of this but you get the idea.
You might want to put some lube to places which could require it to make the throttle wheel move more smoothly. Place a lanyard at the bottom and screw the top case onto place by using 4 screws from the donor remote.
Calibrate your remote. You can reach the bind button with a small screwdriver from a hole on the side of the case, just be careful not to poke anything else while you’re there.
The notch on the thumb wheel acts as a controlled end stop for both directions. I’m sure it would stop without the notch but haven’t tried.
I myself am not looking for different designs but if you or anyone else wants to give it a try I can provide the step file.
Edit: I uploaded the file to Thingiverse.
The remote looks great. I will try to print the files tomorrow and assemble it. I might try to add an on off switch becasue the mini remote on off switch is not too stable.
Awesome remote mod! By far the smallest and one of the best feeling I’ve printed! Don’t have it fully up and running as I’m waiting for batteries and parts and stuff.
First couple things I noticed was that the roll back is lot stiffer than the roll forward which I think is due to the mini remote spring system. Not sure how I feel about it, I’ll have to see how it feels while riding.
Speaking of the trigger mechanism I think my screws where too long as they kinda stick out lol
the roll back is lot stiffer than the roll forward which I think is due to the mini remote spring system
Yeah the spring system geometry causes that. Doesn’t bother me though and I’ve used this kind of a remote since last summer.
By the way, rolling the knob towards yourself means acceleration and forwards is brake! I think you can change this by resoldering the potentiometer wires in a different orientation. I like it the way it is so haven’t tried to crisscross the wires.
I think my screws where too long as they kinda stick out
Mine do too. Didn’t want to make the case even 1 mm thicker so…
I opened these holes so that the screws come neatly through (look at the 1st picture above). Alternatively you could shorten the screws just a little bit.
If you wonder why I didn’t model these as 100% through holes it’s because I think it prints way nicer if the first layer is as uniform as possible. You can always open up a hole but closing it is more difficult.
I also used similar strategy in many other places in the design, i.e. thinking more about the printability of the part.
Have you also considered adding the second pot back to the side to make it usable for third party add on’s?
No. And I don’t think there’s really room for that unless I made a more drastic design change.
And I’m right handed, also with regards to controlling the remote.
I cut a bit of the plastic off the mini remote part to make the thumbwheel go forward a bit for more throw. I also cut the nub off the thumbwheel to allow it to roll further. More throw!
