Bus Transfer / APU Panel

 Strategies
Kit Bashing
All plates need to be trimmed a little to allow easier fitting.

Backplate
Width5.75" (approx 146.05 mm)
Height24 DZUS units (24 x 0.375")
9" (approx 228.6 mm)
Backplate Thickness1/16"
Light Plate Thickness1/4" (0.25")
Module Depthapprox 6" plus connector (estimate)




Simulator Supplier Parts
Hispa Panels145 x 223 mm
Sismo Soluciones146 x 228 mm
CockpitSimParts146 x 240 mm
PC Flights146 x 228 mm


December 2016 prices
Supplierpanelmeterannunpartsknobtotalnotes
Hispa Panels 4514incl24~ 790 €uses small toggles
Sismo Soluciones-Module 18955inclinclincl244 €Assembled with switches
Sismo Soluciones-Panel 56--56 €Front Sub panel only
Open Cockpits 5957incl~ 21~ 7144 €
CockpitSimParts 4035incl~ 21~ 7£ 103
PC Flights $ 594924~ 16~ 7$ 155
STRATEGIES
To Do:
Shown is the panel as supplied by PC Flights assembled with PC Flights supplied meters annunciators and switches.
This panel is the correct size although the width between bolt holes seems to be a bit shy of the DZUS standard (as I understand it). This hole spacing allows the PC Flights DZUS replica bolts to fit without interference with bolts on an adjacent panel.

The challenge is to backlight this panel and meters as well as to provide connection to simulator hardware.
KIT BASHING
Isometric view of completed unit.

  • Get 4 DZUS replica bolts (PC Flights and Sismo both supply them).
  • Fabricate 3 new circuit boards:
  • The first board uses surface mount LEDs to backlight around the toggle switches and annunciators. Note the cutouts to make room for the annunciators.
  • The second board uses surface mount LEDs to backlight around the rotary wiper switch.
  • The third board is for the connectors to the outside world and also has mounts for the interface electronics.
  • Add caps to switch handles (see note below).
  • Solder LED's, resistors, and connectors to these boards.
  • The first board is mounted using the toggle switches. 4-flat-head M3 bolts are mounted to the back panel with nuts spacing the circuit board behind the back panel.
  • The second board is mounted using M3 bolts. One of these bolts is also used in mounting the front engraved panel. The second flat-head bolt is directly bolted to the back panel. A nut is used between the back panel and circuit board.
  • The connector board mounts on spacers attached to the 4 flat-head bolts.
  • Make 1 cylinder to fit around the meter with sufficient allowance for mounting LED lighting strips on the inside of the cylinder. I used 0.022 inch 2-layer actylic sheet from inventables. This sheet cuts easily and is very pliable. I cut the cylinder 1" high to keep from overheating the servos.
  • Glue a row of LED lighting strip along the inside bottom of the cylinder.

    Post Script files for the circuit board

    LED Circuit Boards
    LED Circuit Boards Mirrored
    Connector Circuit Board
    Connector Circuit Board Mirrored




    Here is the end result.
    Circuit boards with LED's, resistors and connectors mounted. The parts are not perfectly lined up, but it's what you get when hand-soldering SMD parts.
    The toggle switches and rotary switch are first mounted on the LED circuit boards.

    Mount the circuit board and switches to the Bus Transfer/APU backplate.
    Side view of assembled unit. Note the circuit board, and led's between the toggle switches and Bus Transfer/APU panel. Also note the rotary switch is mounted to the circuit board.
    Rear View - Note the cylinders around the meter holding the LED strips.


    Switch Caps
    Lowes has a product called "White Screw Protectors" for a 1/4" screw (Hillman # 881038). These protectors fit nicely on the handle of a toggle switch although you will need to add a small cylinder of heat-shrink tubing to the narrow part of the switch shaft.

    Surface Mounting
    Most of the units use CREE CLM1C-WKW-CWBXA453. I wanted 2400mcd brightness, 4500-5650K color temperature, 20ma.
    For a 12V supply, I use 2200 ohm resistors when driving 3 LEDs in a string or 3600 ohm for 2 LEDs