5. RhinoACE - Virpil ACE Pedals FFB Conversion¶

5.1 Overview¶

The RhinoACE is a high-torque conversion kit that adds VPforce FFB capability to Virpil ACE rudder pedals using the 86BLF03 motor. Based on Number481’s design, this kit provides professional-grade force feedback using a pre-assembled aluminum frame for simplified installation.

Key Features:

• Solder-free assembly using pre-crimped wiring
• Compatible with Virpil ACE rudder pedals
• Uses 86BLF03 motor from VPforce DIY kit lineup (high torque)
• Pre-assembled aluminum frame for easy installation
• Requires dual USB connection (original ACE for brakes, VPforce board for rudder axis)
• Adjustable height: ~80mm with feet, ~50mm without feet, ~30mm with horizontal 2040 profile

5.2 Kit Contents and Requirements¶

Included:

• Pre-assembled aluminum frame with mounting hardware (shortened version for sale)
• PETG-printed mechanical components (motor mount, enclosure, lid, spacers, pulley)
• Hardware (M3-M6 screws, nuts, washers, timing pulleys, timing belt)
• Pre-crimped power wiring and USB extension cable

Required Components (not included):

• Virpil ACE rudder pedals
• VPforce DIY FFB kit: 86BLF03 x1 + USB (order from VPforce: 229€ + VAT)
• Power supply unit
• USB type A to B cable

Pricing:

• Kit: 199€
• VPforce motor kit: 229€ + VAT
• Total project cost: ~428€ + VAT (excluding PSU and cables)

5.3 Technical Specifications¶

Mechanical Design:

• Motor configuration: External frame-mounted 86BLF03 (high torque)
• Pre-assembled aluminum frame: Simplified installation with adjustable orientation
• Belt drive transmission: 15T motor pulley to ACE swing arm pulley
• Optional printed throw limiters to replace feather holders

Electrical Configuration:

• VPforce USB board: Rudder axis control
• Original ACE board: Brake axis control (dual USB operation)
• Custom enclosure: Houses VPforce board, power connections, and USB interface
• Pre-crimped wiring (solder-free assembly)
• External DC power supply

Height Configurations:

• With black feet: ~80mm from floor to ACE bottom edge
• Without feet: ~50mm added height
• Horizontal 2040 profile: ~30mm added height (wider underside)

5.4 Assembly Process Overview¶

The RhinoACE conversion uses a pre-assembled aluminum frame, simplifying installation significantly. Full assembly instructions with detailed photos available in original documentation.

Assembly Stages:

1. ACE Preparation: Remove four M6 screws from swing arm, remove spring (not needed)
2. Enclosure Assembly: Install DC power connector, VPforce board with M3×8mm screws, connect power block
3. Motor Installation: Attach 86BLF03 motor to aluminum frame with M6 screws, connect power and data cables
4. Pulley Installation: Mount 15T pulley to motor shaft (height-adjustable), attach pre-assembled pulley to swing arm with M6×20 screws
5. Base Modification: Remove original feet construction and bottom plate, install new M2×20 screws with spacers
6. ACE Mounting: Attach ACE to aluminum frame using modified mounting points (leave screws loose initially)
7. Software Configuration: Set up VPforce configurator with unique Device Ident and Product ID
8. Belt Installation: Tension belt between pulleys with ACE positioned correctly, use wooden block or two-person method
9. Final Assembly: Tighten frame mounting screws, install lid, perform calibration

Critical Assembly Notes:

• Original M6 swing arm screws and spring should be stored for potential kit removal
• Belt tensioning requires wooden block or two-person assistance (prevent cable damage)
• 15T pulley height must match ACE pulley before final tightening
• Bottom plate spacer sequence: M2×20 screw → washer → bottom plate → black spacer → original washer → M5 lock nut
• Motor labeled “Y” may require Swap checkbox activation or firmware reflash
• TelemFFB identifies pedals by single X-axis configuration (disable Y-axis in configurator)

5.5 Software Setup Summary¶

Initial Configuration:

1. Connect VPforce board via USB (disconnect other VPforce devices)
2. Access firmware update via Edge or Chrome browser
3. Download and run VPforce FFB Configurator

4. Configure three critical settings:

   • USB Device Ident: “RhinoACE” (or unique name)
   • USB Product ID: 2054 (or unique ID)
   • Disable Y-axis (required for TelemFFB pedal detection)

5. Set Master Gain: 100%, Spring Gain: 100% for belt installation

6. Manual calibration values: min: 0, max: 4096 (centers motor axis)
7. Motor labeled “Y”: Activate Swap checkbox or contact Walmis for firmware reflash
8. Perform auto-calibration after belt installation
9. Fine-tune gains, spring, and effects per user preference

TelemFFB Integration:

• Configure VPforce-TelemFFB application
• Multi-device setup: Configure Launch Options with RhinoACE ID for simultaneous joystick/pedal operation
• Auto-Launch and headless mode for seamless game integration
• Simulator compatibility: DCS World, IL-2 Great Battles, MSFS, X-Plane

Configuration Resources:

• Hiob’s starting configuration (VPforce Discord)

5.6 Optional Modifications¶

Original Feet Restoration:

• Remove printed feet and reinstall original Virpil ACE feet if preferred

Throw Limiters:

• Replace feather holders with printed throw limiters for customized pedal travel limits

5.7 Performance Demonstration¶

Demo Videos:

• Spring force varying with speed (RhinoMFG with 57 motors)
• Pre-stall buffet effects (RhinoMFG with 57 motors)
• Virpil ACE FFB demonstration

5.8 Additional Resources¶

Assembly Documentation:

• Detailed Assembly Guide (step-by-step instructions with photos)

General FAQ:

• FAQ - RhinoACE DIY Kit
• FAQ - General DIY Kits (PSU requirements, shipping, payment, warranty)

Community Support:

• VPForce Discord: Real-time assembly guidance, troubleshooting, and configuration sharing
• Multi-device configuration support (running RhinoACE with Rhino joystick/collective)
• User settings database and community configurations

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Project Credits:
Original design by Number481 | Kit assembly and documentation by Kaltokri | VPforce motor electronics by Walmis