Throughout all of our controller redesigns, we've also found that a lighter handle equals a better feel for the driver. The return spring on the KOP joysticks is quite small, and the extra weight of the taller, bulkier handle creates a very floppy feeling.
By making the handle lighter, and shortening it's overall lenght, the "tightness" of the joystick can by adjusted to your liking. Two years ago, we machined short, solid handles from HDPE, and were pretty happy with the results. This year, we switched to hollow PVC handles with HPDE endplugs. These were a bit lighter, and therefore, gave an even better feel for our drivers.
I believe our national champs decided to use screwdrivers as their joystick handles. Doesn't get much easier than that!
Team 296 Operator Interface
BEN