The Unused Voyager Tricorder V2

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MangyDog

Sr Member
So amongst going back to my stargate project files today and cleaning them up before i make some more alterations to that before i start printing again.... Prep stuff.... I also today designed the new hinge idea.....
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MangyDog

Sr Member
This has far from been easy.......

Ive had a right nightmare with the brass lately. Not making the hinges so much... ill get to that, but just getting hold of it...

I got some brass sheets a few weeks back but at the time I had no way to cut into strips.

So I found a shop that was selling 4mm wide strips... Perfect.... Only I find out 2 weeks after placing the order that they were out of stock...

After wasting sooo much time waiting for that, I tried to cut some strips on my bandsaw and nope, the blade I had was too course and blunt and wouldnt cut the brass...

So I found a blade on amazon that was 24 teeth per inch, perfect... Checked the size to what I thought was the size of blade on my saw.....

And nope... I try installing the blade after delivery and it was too small... I reread the specs on my saw and found I was reading the wrong measurement
Anyway turns out my saw doesnt have a terribly common saw length, so i had to order a made to order band blade...

Slightly more expensive and had to wait several more days yet again......

But at least now after several weeks, Ive managed to start

Im not going to lie this project like many of mine, is starting to get overly complicated.

Anyway


Soooo heres the strips

IMG_20210317_150539.jpg


I intentionally slightly over sized the width as I knew the edge wouldnt be clean, So i cut back all the rough edges.
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Double checking it fits.
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bunch of strips......
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one tricorders set of loops.
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Soooo i made a little mistake.
I need to cut another strip as I dont have enough hoops for all three hinges.

But damn this is being a super pain.... The brass is hard which is good... but its also really difficult to shape. Im using pliers and a vice to help shape the hoops... And its taken several several hours to just make this one set of hoops...

joy! :(

Anyway its getting done!
 

MangyDog

Sr Member
So ive been dealing with these hinges for the last several days and thats it.... IM DONE WITH IT! no really theyre done :D

Though Im also done with it... cant say how fed up i am with them but so glad that theyre (mostly) done.

So first task was to take my cut strips and make the hoops. I first bent the strips using pliers into a rough u shape, and placed the 2mm steel rod I was going to use as a pin, into the middle. Then placed the strip into the vice and clamped it down at multiple angles till i had my shape. To make each hoop, took roughly 10 to 20 minutes each and was just the beginning of the tediousness of this task...

I also soldered half the hoops to add strength and to stop them opening over time.

IMG_20210319_230813.jpg
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To help make the hoops more uniform and to remove all the humps and bulging from bending and some of the dents, i placed all the hoops on a length of rods ans filed them back and round
IMG_20210319_183744.jpg



After chopping up the pins and started placing them into the frame to test and figure out how im going to messure and bend the strips to fit.......
IMG_20210319_155542.jpg




In the end it took me ALLLLLL DAY today (and several hours yesterday) to finally fit all the strips and I had to go by eye and figure out where to bend it... Fiddly as hell is an understatement.!

It genuinely took far too long and Im kinda inclined to slightly rework the design to make it a little easier in the future... If i can be arsed to be honest.

IMG_20210320_222307 (1).jpg



Because everything is eyeballed... they dont all quite line up perfectly.... They should be fine for the tricorders, but the protectionist in me is really tweaking here...

And when fitted, things might not perfectly close without perfect zero gaps.......... oh well....
At this stage Im forced to go with its good enough! Just so i can be DONE with this and get back to the rest of the thing!

Anyway

HInges are done... for now. Well not quite, i still need to solder the ends of the pins to the brass and then dremel them back flat... But must put on a mask, using leaded solder!
 

MangyDog

Sr Member
Finally... hinges done and ready to install... Gonna be doing that today, and hopefully ill be closing up the tricorders over the next couple of days and ready to finish painting and programming.......... sighs! this has been a horribly long winded nightmare
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gmprops

Sr Member
RPF PREMIUM MEMBER
I wanted to keep true to the concept design and my previous version with 2 hinges... But im curious, what did they use the third hinge for in the endgame tricorder?
The third hinge was never used , at least in the electronics I designed. I had separate circuit boards for the main body and the door. All they needed was power. I was scheduled to do a run for Roddenberry.com back in the early days, but it never happened.
 

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gmprops

Sr Member
RPF PREMIUM MEMBER
So ive been dealing with these hinges for the last several days and thats it.... IM DONE WITH IT! no really theyre done :D

Though Im also done with it... cant say how fed up i am with them but so glad that theyre (mostly) done.

So first task was to take my cut strips and make the hoops. I first bent the strips using pliers into a rough u shape, and placed the 2mm steel rod I was going to use as a pin, into the middle. Then placed the strip into the vice and clamped it down at multiple angles till i had my shape. To make each hoop, took roughly 10 to 20 minutes each and was just the beginning of the tediousness of this task...

I also soldered half the hoops to add strength and to stop them opening over time.

View attachment 1438888 View attachment 1438889

To help make the hoops more uniform and to remove all the humps and bulging from bending and some of the dents, i placed all the hoops on a length of rods ans filed them back and round
View attachment 1438890


After chopping up the pins and started placing them into the frame to test and figure out how im going to messure and bend the strips to fit.......
View attachment 1438892



In the end it took me ALLLLLL DAY today (and several hours yesterday) to finally fit all the strips and I had to go by eye and figure out where to bend it... Fiddly as hell is an understatement.!

It genuinely took far too long and Im kinda inclined to slightly rework the design to make it a little easier in the future... If i can be arsed to be honest.

View attachment 1438893


Because everything is eyeballed... they dont all quite line up perfectly.... They should be fine for the tricorders, but the protectionist in me is really tweaking here...

And when fitted, things might not perfectly close without perfect zero gaps.......... oh well....
At this stage Im forced to go with its good enough! Just so i can be DONE with this and get back to the rest of the thing!

Anyway

HInges are done... for now. Well not quite, i still need to solder the ends of the pins to the brass and then dremel them back flat... But must put on a mask, using leaded solder!
That is pure genius. A lot of work, but still genius. I am very impressed with your solution.
 

MangyDog

Sr Member
That is pure genius. A lot of work, but still genius. I am very impressed with your solution.
Thanks Gerry :D How genius this is, is yet to be seen.... Ive been through this hinge design so many times and previous ones ended up failing sooooo lets hope the brass holds out better. And the physical connection inside is stable enough for serial to go through without too much error correcting.

Ill be adding packet checking code to the program.

Though fitting them hasnt been simple either... and having to sand back bits off the frame... Why cant things just be easy :D
 

MangyDog

Sr Member
Sometimes I just want to curl up in the corner and cry......

This new tricorder has turned into a total nightmare.... At every step of the way I have had new problems to deal with and things just not working out as they should... From the issues with the lcd to bad board designs to failing hinges and now.... PAINT! (and some electronics woes)

As Ive mentioned before I have some one whos been incredibly patient waiting for their prop for a LONG time... well well over a year now. And I really had hoped to have finished this new version by last Christmas, Were now at April the 1st, No don't worry no April fools joke about me quitting the project. But damn do I want to.

And its also this poor guy waiting thats making me stay with it. Even though Id like to take a break from it.

Anyway progress has been made and I thought the doors were made and ready to attach to the main bodies and then I could install the rest of the electronics and glue the main body shut, fill in the gaps and have it ready to paint...... BUT NOOOOoooooo... Why would it ever be THAT easy!

So having a good warm couple of days I took the opportunity to paint the doors and lacquer them.

After painting I left them outside int he sun for an hour or so... I decided to take a nice break and head to the local beach to go for a walk because lockdown had really been bad cabin fever was setting in and I needed the break.

IMG_20210401_115210.jpg


Ive already repainted these 2 times, because I had already had to crack them back open to replace the old hinges, and do more filler work. But also because when I tried painting them before the warm spell we just had, the lacquer bloomed.

The first issue I found right away was when taking the masking off....... It didnt come with a clean edge.
IMG_20210401_115253.jpg
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Pealing some of the paint with it revealing the filler primer.
AGHHHGHHGHGHGHHHGHGHGHHHHHHHHGHHGH!

Because of the way the electronics are placed inside before its painted, Its impossible to not have certain things in like the emergency button frame and the ID button placed in before painting. SO they had to be masked.

I think part of the issue is I'm using bumper paint rather than body paint. Thats only because its near enough the same colour as what I used on my first tricorder build. I guess it has a slightly more flexible element to it that makes it not cleanly mask off.

I might be able to mix up some model paint again and get it close to this colour, then gently sand those edges and paint it in, mask again and give it a little dusting of lacquer and hopefully it would blend in well enough. But its just MORE headache and more things stopping me from continuing.


But thats the easy problems to fix....

This is much..... MUCH worse!

IMG_20210401_115349.jpg

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Some how, and i guess when I was last cracking it open the vinyl covering on the decal got damaged... As it was all under the masking I didnt see it happen.

Really this made me want to just fall down and blub... The only way to fix this is to again crack this door open then break all the epoxy glue holding the pcb down then peal the vinyl hoping not to damage the decal before puttng on some new wrap.

But thats not all thats wrong with this door...
When looking closely at this door i noticed something wasnt right with the leds...
IMG_20210401_121020.jpg

Spot the difference...
IMG_20210331_223531.jpg


I guess from flexing as i cracked the door open, the phosphorous broke off from the LEDS... (the yellow stuff) I dont think I accidently put a coloured led on those pads. But ive been so hetic on this it could have been the case. So I soldered a power cable to the hinge and programmed it with my led test program, and indeed. Those leds are not working at all.

i guess, "luckily" as i have to crack this open to fix the vinyl.... Ill be able to fix this too! joy!


IMG_20210401_115313.jpg

Oh and yes there is a crack there..... happened at the cracking open of the door last time, thought I fixed the actual crack but it traveled further than i thought... should be easy enough to fix with some super glue.

All in all.... I dont want to make any tricorders ever again after all this.

I really need to work more on redesigning the process to make it simpler to build. This really has turned into an utter nightmare.

Simply put if Im to make more I need to charge A LOT more than what I've already agreed to. Which will make these far far more expensive than anyone would ever want to pay for a tricorder.
 

MangyDog

Sr Member
Well this time i just wasnt able to take the face off without breaking it :/ Gonna have to reprint that.
I also damaged the mini screen, so going to have to replace the decal on that as well as the damaged button decal :/

effing whelp!
IMG_20210401_164950.jpg


Interesting side note, the leds dies were ripped off.... Must have been done when I last took the face off
IMG_20210401_165021.jpg
 

MangyDog

Sr Member
So finally after loads of headaches this last few weeks dealing with hinges and painting and sealing the doors.... I FINALLY started installing the electronics in the main bodies of the three tricorders im building.

Second one is now nearly done. Third to do tomorrow...

As always nothings been simple. Little strange soldering issues have popped up and then the very fiddly installation work.

While I wont do it now. I might end up making a v3 version of this tricorder. With revised PCBs and even newer hinges.......
Just to make it easier to install, wire up and build.

Also the hinges.... sighs. Theyre not perfectly aligned. So the doors aren't perfectly lined up and when its closed its not perfect. Ill try hiding some of it with filler and sanding but its not going to be as I designed.

Ive hit the point in this project of accepting good enough rather than perfect. As its just taking too long.

The v3 will be better for sure as Ive already come up with a better more accurate hinge design that shouldn't possibly have alignment issues. as they will be printed and built into the door and body with the brass barrels screwed in precise locations.

But as for V3 who knows when Ill do it. Not this year. Far too much on my plate to deal with.

Hopefully the three tricorders will have all the electronics installed, and the seems filled and sealed up, and maybe some painting done by the weekend.

All that would be left is maybe 3 weeks worth of hardcore fueled by coffee demented programming! And it would be done!

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