Instrument Transfer Switch Panel

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

Backplate
Width5.75" (approx 146.05 mm)
Height16 DZUS units (16 x 0.375")
6" (approx 152.4 mm)
Backplate Thickness1/16"
Light Plate Thickness1/4" (0.25")
Module Depth??????????????????????????????????


Simulator Supplier Parts
Hispa Panels146 x 145 mm
Sismo Soluciones146 x 152 mm
CockpitSimParts150 x 160 mm


December 2016 prices
Supplierpanelpartsknobtotalnotes
Hispa Panels 309~746 €(uses small toggles)
Sismo Soluciones-Module 119inclincl119 €Assembled with electronics, knobs
Sismo Soluciones-PanelPanel not found
Open Cockpits 25~ 13~ 745 €Short version of panel (+ components)
CockpitSimParts 25~ 15~ 7£ 47(+ components)
PC Flights 27~ 16~ 7$ 50
STRATEGIES
To Do:
Shown is the panel as supplied by PC Flights assembled with PC Flights supplied 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 2 new circuit boards:
  • The first board uses surface mount LEDs to backlight around the toggle switches.
  • The second board is for the connectors to the outside world.
  • 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.
  • The connector board mounts on spacers attached to the 4 bolts coupling the front panel and backplate


    • Post Script files for the circuit boards

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




    Here is the end result.
    Circuit board 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 board.
    Mount the circuit board and switches to the Instrument Transfer backplate.

    Side view of assembled unit. Note the circuit board, and led's between the toggle switches and Fuel panel. Also note the rotary switch is mounted to the circuit board.
    Wiring to connector circuit board.


    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