There's a design flaw in this unit, which causes the wiring inside to eventually snap from fatigue. The right toe brake on mine failed way back in 2005, but I decided to finally have a go at fixing it. Basically you take the unit apart, peel some of the insulation off, solder the wire together again, put some tape on any other wire where the insulation looks frayed or damaged and re-assemble the unit. If you have been using the unit for a few years and everything still works, it might still be a good idea to open it up and check the wiring. Maybe you can reinforce the insulation with some tape before one of the wires snap completely. After doing this, the unit works great again except for one thing. The right toe brake is constantly sending about "16" even after calibrating. With the wire snapped, it was obviously sending "255" all the time, so it's definitely an improvement. Just wondering why it might do this and if there's any way to fix it (I should be able to just set a small dead-zone in FS, so it should not really be a problem). I'm guessing that either my soldering caused some additional resistance in the wire (I can't solder. I managed to create a big fat lump on the wire), or the pot is simply a bit scratchy (remember I haven't actually used the toe-brake since 2005). If I step on the pedal with my heel, it actually goes to zero, so I'm thinking it might be the pot. But why doesn't calibration fix this, isn't that what calibration is meant for?

Why don't you calibrate in FSUIPC? Cheers, - jahman.

Windows7 calibration does not work properly with CH products. Either use the CH Control manager of FSUIPC. Vic

If you do have a cold solder joint, you are not going to get a good calibration until it is repaired. http://www.ehow.com/how_376_solder-wires.html

Why don't you calibrate in FSUIPC? Cheers, - jahman.

Because I don't have FSUIPC :)

Windows7 calibration does not work properly with CH products. Either use the CH Control manager of FSUIPC. Vic

Thanks, will try that. I had even forgotten that CH make their own control manager application.

If you do have a cold solder joint, you are not going to get a good calibration until it is repaired. http://www.ehow.com/...lder-wires.html

Yeah, it could be the solder joint, but then again, as long as I keep my foot on the rudder pedal, the brake does not engage. But if I step on the toe brake and then immediately let go, it sticks at a value of around 16/255. This makes me wonder whether it might just be the potentiometer acting up. Maybe it will loosen up after some use, after all, it hasn't been used at all for six years..

Because I don't have FSUIPC :)

Well, maybe you should get FSUPC? Cheers, - jahman.