The next step was to get the controls under control.. get it.. ??
CONTROLS under
CONTROL... :unsure... <<< crickets >>>
Anyway, the control box plus battery compartment was next.
When I did my Guy Manuel, I used a project box with battery holders to fit 6xAA batteries for a +9V system. Like this
However, AA batteries (rechargeable or not) are bad in the following areas:
- High self discharge rate,
- accelerated voltage drop under load, and
- expense of batteries.
So, I quickly changed to LiPo batteries. I'm currently using a 2S1P Lipo pack that I was using for my electric RC buggy. Here's the pack I'm using:
I like these packs because they have integrated female bullet connectors and they have a hard case.
So my challenge is to rig something that will integrate easily to this pack.
Here are all the controls and components used for this adapter.
So, I have the multi-position pot switch, 2 power switches (one for the LED Matrix and one for the side boards), male bullet connectors and female headers.
Firs step was to connect everything to make sure it worked!
Then I started working on the case.
I made sure that the wires did not touch the walls of the casing.
In the picture above, you can see how I used spare female connectors to hold the male connectors in place.
I used this putty to seal the corners. I didn't want all the liquid resin to leak before curing.
Now, prepping for the casting resin
... poured the 'good stuff' through the opening. Wow! this thing gets hot while curing.
Did a quick continuity check to make sure all components survived the casting resin and they did. :thumbsup
However, I did not pull the female connectors soon enough, so they bonded somewhat to the male connectors. One of them was so welded that I eventually pulled the entire connector out. :angry
Luckily, i could see where the connecting wire was
I re-solder the connector and using JB Weld placed the male bullet connector back in its spot.
After sanding a bit and a coat of black paint, my adapter control unit was fully functional AND more aesthetically appealing.
Trust me.. changing batteries is a 2 second operation.
I also sandwitched a piece of styrene between the battery pack and this control box and used it as a belt clip for a very slim design.
:love