[ARCHIVED THREAD] - Emcomm Box Construction - Getting Closer ***New Pics - Radios on Bottom*** (Page 2 of 8)
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also, get a layer of heatshrink tubing, or better yet two, over the FASTONs connected to the IEC power inlet. during AC operation they are sitting at 120Vac and that is not metal you want exposed at ANY time. ar-jedi 
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See if you can remove the sticker shown here..................................... http://home.comcast.net/~gregbell/Panel%20Rear%20Wiring%20BTJ.jpg And place it on the front of the panel under the tender. Good idea about moving this sticker, Cyclic. 
There's a simpler description visible on the front of the B.T. Jr, but I also prefer this one. |
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also, get a layer of heatshrink tubing, or better yet two, over the FASTONs connected to the IEC power inlet. during AC operation they are sitting at 120Vac and that is not metal you want exposed at ANY time. ar-jedi http://losdos.dyndns.org:8080/public/ham/races-box/construction/IMG_1814_sm.jpg Understood about the exposed 120Vac terminals, ar-jedi. These are the parts I have been waiting on, along with a right angle power lead for the power supply to "Y" in behind the 120Vac receptacle. 
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Where are you guys getting the digital volt meter? I've seen some 3 1/2" ones on Ebay for like $10.00. Thanks bishop2355 Archived Original Post I'm almost ashamed at how cheap this voltmeter was. Got it from Ebay for $9.99 delivered. The only thing that concerned me was it comes directly from China. I do like to buy American when ever I can, but I took a chance this time 'cause I didn't want to spend a fortune on a volt meter. I was pleasantly suprised at the great communication and prompt shipping from this dealer. The dealer's name is "Giorgio". Blue LCD DC Volt Meter I PayPal'd the $ and had the meter in about 10 days. ETA: It reads 0.05 VDC higher than my Fluke 77 that's more than 10 years old. |
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be sure that whatever meter you purchase has "isolated inputs" and can measure a voltage referenced to it's own power source ground. this is not the case for the majority of really inexpensive meters. most of these are designed to be powered by a 9V battery, and not the voltage source it is trying to measure. ar-jedi |
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did you measure the backset for the radio mounting bar against the depth of the accessory tray, or did you have another idea? the way i did mine (not necessarily the right way, just *a* way) was such that the accessory tray just kisses the mounting bar. and of course the switch panel has to clear it as well. ar-jedi 
ps: 
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I plan to mill out a recess for each and secure them to the board. http://home.comcast.net/~gregbell/Bread Board 3.jpg note to future box builders: use a cutting board or similar (per above) instead of plywood like i did. when i routed my bottom panel i had significant "edge tear out" at the periphery due to the plywood lamination. this will not happen with a solid material such a Delrin or other HDPE material cutting board. also, there must be a better (more clever, less brute force) way to securely hold the battery and power supply to the bottom of the box, but i haven't found one... 
ar-jedi 
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did you measure the backset for the radio mounting bar against the depth of the accessory tray, or did you have another idea? the way i did mine (not necessarily the right way, just *a* way) was such that the accessory tray just kisses the mounting bar. and of course the switch panel has to clear it as well. ar-jedi http://losdos.dyndns.org:8080/public/ham/races-box/construction/DSCN1191-annotated_sm.jpg http://losdos.dyndns.org:8080/public/ham/races-box/construction/DSCN1193-annotated_sm.jpg ps: http://losdos.dyndns.org:8080/public/ham/races-box/construction/IMG_1808_sm_annotated_sm.jpg Yes, I did measure the backset for the radio mount bar. It's approximately the same as yours (4.3"). The mounting of the FT-8800 appears to set quite a bit further forward than the Icom V8000. By that, I mean the face of the FT-8800 sets about 3 inches forward of the mounting bar. It looks like the Icom V8000 is closer to flush with the mounting bar. I may need to rework or remake the mounting bracket to set back the radio more if the tray is used in the box, or modify the tray, as you did. (very nicely, I must add. )
I have not settled on how far to set back the switch panel, yet. Still toying around with mounting ideas. |
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AR, have you thought about maybe using some threaded rod and a piece of flat stock aluminum drilled for the rod then a couple of washers and wing nuts to secure everything to the board? i said "clever", not "ghetto". 
ar-jedi it doesnt have to be getto. LOL. you could use sleeves to cover the threaded rod and even paint the aluminum. auto makers have been using this type of battery hold down for years. |
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See if you can remove the sticker shown here..................................... http://home.comcast.net/~gregbell/Panel%20Rear%20Wiring%20BTJ.jpg And place it on the front of the panel under the tender. Good idea about moving this sticker, Cyclic.
There's a simpler description visible on the front of the B.T. Jr, but I also prefer this one. OK....I tried to remove this sticker and put it on the front of the panel, but I can't get the darned thing off without the edges tearing. 
Ideas, anyone 
PS: I even emailed Battery Tender to try to get another sticker, but they said they don't have any available.
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stupid answer? take a pic of it and print it out then laminate it with a cold lamination pack from walmart. there in the office supply section with either the pens or the next isle with the envelopes. Ya know it costs like a buck fifty to get small stuff like that hot laminated at Kinkos, right? It's worth a trip, if you ask me. |
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stupid answer? take a pic of it and print it out then laminate it with a cold lamination pack from walmart. there in the office supply section with either the pens or the next isle with the envelopes. Ya know it costs like a buck fifty to get small stuff like that hot laminated at Kinkos, right? It's worth a trip, if you ask me. i just suggested that because he can print out the pic at walmart while he is getting the cold laminate. guess he could do the same at kinkos to though. |
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stupid answer? take a pic of it and print it out then laminate it with a cold lamination pack from walmart. there in the office supply section with either the pens or the next isle with the envelopes. Doh! I even took a picture already, and I can get it laminated at work.  <––––––Me not seeing the obvious.
Thanks. 
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Quoted: Hard to see the forest for the trees.Quoted: stupid answer? take a pic of it and print it out then laminate it with a cold lamination pack from walmart. there in the office supply section with either the pens or the next isle with the envelopes. Doh! I even took a picture already, and I can get it laminated at work. <––––––Me not seeing the obvious.Thanks. |
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Quoted: Quoted: AR, have you thought about maybe using some threaded rod and a piece of flat stock aluminum drilled for the rod then a couple of washers and wing nuts to secure everything to the board? i said "clever", not "ghetto". ar-jedi How about an actual vehicle battery clamp? Hook the bottom hooks of the legs through slots in the cutting board and put wing nuts on top. |
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Quoted: Quoted: Quoted: See if you can remove the sticker shown here..................................... http://home.comcast.net/~gregbell/Panel%20Rear%20Wiring%20BTJ.jpg And place it on the front of the panel under the tender. Good idea about moving this sticker, Cyclic. There's a simpler description visible on the front of the B.T. Jr, but I also prefer this one. OK....I tried to remove this sticker and put it on the front of the panel, but I can't get the darned thing off without the edges tearing. Ideas, anyone PS: I even emailed Battery Tender to try to get another sticker, but they said they don't have any available. Spray it with WD40. It'll come loose. Stick it where you want it and cover it with clear fingernail polish.....or just take a color photograph, print it, cut it out and do the fingernail polish bit. |
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stupid answer? take a pic of it and print it out then laminate it with a cold lamination pack from walmart. there in the office supply section with either the pens or the next isle with the envelopes. Doh! I even took a picture already, and I can get it laminated at work. <––––––Me not seeing the obvious.
Thanks. sometimes the simplest answer is the best. |
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OK folks, back in action after regaining some manual dexterity after cutting my thumb at work. (8) stitches worth.
These pics are trial fits only. Still need to secure the PS, batteries, grounding block, add crimp on pin connectors for ground wires, shrink the heat shrink, and secure the Wago 120Vac splitting terminal. I milled a 1/4" recess in the 3/4" cutting board for the power supply and batteries to fit in. 
Panel wired, but not zip tied yet until checkout. 
This is the Wago terminal that splits the 120Vac input into two outputs, one each for the B.T. Jr. and the PS. I was looking for a good way to "Y" the input and came across this. 
Everything works, but I wired the display source switch backwards for the PS voltage. I changed the Powerpole 12Vdc output block from a 2x3 to a 2x4 and corrected the orientation. 
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Where are you guys getting the digital volt meter? I've seen some 3 1/2" ones on Ebay for like $10.00. Thanks bishop2355 Archived Original Post I'm almost ashamed at how cheap this voltmeter was. Got it from Ebay for $9.99 delivered. The only thing that concerned me was it comes directly from China. I do like to buy American when ever I can, but I took a chance this time 'cause I didn't want to spend a fortune on a volt meter. I was pleasantly suprised at the great communication and prompt shipping from this dealer. The dealer's name is "Giorgio". Blue LCD DC Volt Meter I PayPal'd the $ and had the meter in about 10 days. ETA: It reads 0.05 VDC higher than my Fluke 77 that's more than 10 years old. OK, I bought one of those $10 blue LED volt meters from Giorgio. It was off a hair. On the back is a multiturn pot. I just put my DMM in parallel with it on one of my backup batteries and dialed it in to read the same as my DMM. |
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Where are you guys getting the digital volt meter? I've seen some 3 1/2" ones on Ebay for like $10.00. Thanks bishop2355 Archived Original Post I'm almost ashamed at how cheap this voltmeter was. Got it from Ebay for $9.99 delivered. The only thing that concerned me was it comes directly from China. I do like to buy American when ever I can, but I took a chance this time 'cause I didn't want to spend a fortune on a volt meter. I was pleasantly suprised at the great communication and prompt shipping from this dealer. The dealer's name is "Giorgio". Blue LCD DC Volt Meter I PayPal'd the $ and had the meter in about 10 days. ETA: It reads 0.05 VDC higher than my Fluke 77 that's more than 10 years old. OK, I bought one of those $10 blue LED volt meters from Giorgio. It was off a hair. On the back is a multiturn pot. I just put my DMM in parallel with it on one of my backup batteries and dialed it in to read the same as my DMM. That's what the little blue component is? Nice discovery, AFM. 
Bochen 3296 Multi-turn trimming pot 
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Personally, I would be a LOT more concerned with insulating
this than 
this. Out of curiosity, how many wires are in the solderless connector? With Faston-style connectors, you are somewhat limited. Have you considered a different switch that uses screw terminals? |
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Sure, if you get out the Acme Electron Microscope!!
You're right. That switch with all the wires connected to it isn't the strongest link in this design, IMHO. There are (3) 12 AWG wires shoehorned on that particular connector. They're 12VDC as opposed to the 120VAC on the power inlet module. Still, no excuse for the sloppy insulating job. Thanks for pointing it out. |
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That's what the little blue component is? Nice discovery, AFM.
Bochen 3296 Multi-turn trimming pot http://home.comcast.net/~gregbell/Meter Back.jpg Why else whould there be an adjustment on the back of a voltmeter?
Oh, it's a multiturn pot. You have to turn it a lot of turns to notice much difference in reading. BTW, ARjedi said something about its operating voltage. Jedi, the meter runs off the voltage it is measuring, and needs 5 volts to operate. No separate battery required. |
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how did you attach the DIN rail for the terminal block? ar-jedi Double sided tape on the bottom of the rail, and on the side of the block facing the B.T. Jr., if needed. Probably will need a more permanent attachment method ( tie-wrapped to the B.T.?) as soon as heat from the B.T. loosens the tape. The shortened AC wiring keeps the terminal from moving a lot. |
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You have done an excellent job on your box. I think it is fantastic. I will offer this bit of advice: Change those bolts that are exposed on the outside of the box. First use button head socket cap screws, your skin will thank you later.http://www.fastenal.com/web/products.ex?N=999600043+1199895768&Nty=0 Second use fender washers under the button heads to spread the load across a bigger area and prevent breakouts.. If your worried about looks paint them to match box color. Third use stainless fasteners. You are already worried abotu waterproofing than why not waterproof your fasteners. Nothing looks worse than a nice box with rust streaks. Any moisture is going to attack those fasteners after a period of time. You not would not believe how much money you guys have cost me with these post of EmComm boxes. I found a use for some of the radios I had laying around. |
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You have done an excellent job on your box. I think it is fantastic. SNIP Thanks SandHillsHillbilly! Good ideas. I'll change out the mounting hardware as you suggested ASAP. 
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SNIP You not would not believe how much money you guys have cost me with these post of EmComm boxes. I found a use for some of the radios I had laying around. Everyone knows it's ar-jedi's fault!
Posted Via AR15.Com Mobile |
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Big Daddy-I hope you don't mind, but I have created a folder on my PC entitled "EMCOMM Inspiration" and have downloaded your pics, descriptions, URLs etc into the folder. I've been following your project closely, and I sincerely appreciate all of the effort you have made toward keeping us updated with your progress. Your large, high-quality images and detailed descriptions have been most helpful.
Thank you
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Big Daddy-I hope you don't mind, but I have created a folder on my PC entitled "EMCOMM Inspiration" and have downloaded your pics, descriptions, URLs etc into the folder. I've been following your project closely, and I sincerely appreciate all of the effort you have made toward keeping us updated with your progress. Your large, high-quality images and detailed descriptions have been most helpful. Thank you No problem CJan_NH. Glad to help someone else go broke whenever I can!
I have a similar folder full of cool ideas and pics from a lot of folks around here. |
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No problem CJan_NH. Glad to help someone else go broke whenever I can!
You've got that right brother!
AR_Jedi is officially on Mrs CJan's shit list. Recently I was shopping for an all mode base radio and I posted a thread asking if the Icom IC-7000 was worth the $300 premium over the IC-706MkIIg. Jedi was very helpful and pointed out that it was worth the upgrade, and he also took the time to explain why. Long story short, my wife saw the thread and said "Who's this Jedi character? You're going to buy the more expensive "CB" just like that...just because HE said so?"
And don't get me started when the wife saw pics of his EMCOMM box (and yours!) Clearly, Jedi gets blamed for everything that goes on in this forum... |
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Clearly, Jedi gets blamed for everything that goes on in this forum... once again, i have to point out that it's not my fault.
lack of prudent fiscal governance in your household can not possibly be the result of me posting pictures on the web.
ar-jedi ETA: besides, this thread distresses me. it makes my orange box look like a hastily-slapped-together prototype.
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lack of prudent fiscal governance in your household can not possibly be the result of me posting pictures on the web.
ar-jedi After being together for almost sixteen years Jedi I've come to realize that my lovely wife just likes to bitch sometimes
While we're certainly not wealthy, we're definitely not living check to check. It's not like I hang out in bars, go to strip joints, or mainline my disposable income. As far as I'm concerned, there are far FAR worse things I could be spending my money on. That's my story and I'm sticking to it!
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lack of prudent fiscal governance in your household can not possibly be the result of me posting pictures on the web.
ar-jedi After being together for almost sixteen years Jedi I've come to realize that my lovely wife just likes to bitch sometimes
While we're certainly not wealthy, we're definitely not living check to check. It's not like I hang out in bars, go to strip joints, or mainline my disposable income. As far as I'm concerned, there are far FAR worse things I could be spending my money on. That's my story and I'm sticking to it! I turned to this hobby because I was spending too much $$$$ on "Black Rifles". 
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