So the usual way I would fix this is to set the Orientation constraint's Transform Rule to Local > Local. However, this won't work for your model because there is an offset (the constrained bones have +X point to the next joint, and the FK and IK bones use -Z) so you are using "Keep Initial Offset". I was able to fix it by…
You're goal doesn't sound complex. Is this similar to what you want to do? I just used a couple of look at constraints. https://dl.dropboxusercontent.com/u/2904948/Tutorials/ArmRig.max
Maybe you can try and HD Ik chain. It works well for mechanical joints. In this example grab the brown box, and move it around. The shoulder and upper arm joints have their axis disabled in the Hierarchy Panel > IK. https://dl.dropboxusercontent.com/u/2904948/Tutorials/ArmRigIK_HD.max
You need to set the UpNode of the "Y LookAt Elbow" object in the LookAt Constraint Options rollout. On the leg the name of the Upnode is ThighController. By default the Z axis will try to point up. Notice in the GIF how in the No Upnode setup the Z axis twists to point up. In the Upnode setup I set the Y axis to point to…
https://dl.dropboxusercontent.com/u/2904948/Tutorials/fubar01.max The trick isn't to rig one system that can do everything. It's to layer objects on top of the rig that isolate single axes. I didn't use anything complex, just look at constraints and HI solvers. This example isn't perfect. If I had more time I could…
Ok I have spent the last two days on this particular problem and cant come up with a solution. I am attempting to create a helper system for this custom rig. The tutorials I found assume a HI IK. Unfortunately while I can get a HI IK to work as a separate IK chain with the other bones attached, it cannot interpret the wire…