Standby Power Panel

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

Backplate
Width5.75" (approx 146.05 mm)
Height11 DZUS units (11 x 0.375")
4.125" (approx 104.775 mm)
Backplate Thickness1/16"
Light Plate Thickness1/4" (0.25")
Module Depth????????????????????????????????????????


Simulator Supplier Parts
Hispa Panels145 x 103 mm
Sismo Soluciones146 x 105 mm
CockpitSimParts150 x 100 mm
PC Flights146 x 105 mm


December 2016 prices
Supplierpanelannunpartstotalnotes
Hispa Panels 29incl1342 €
Sismo Soluciones-Module 96inclincl96 €Assembled
Sismo Soluciones-PanelPanel Not Found
Open Cockpits 27incl1239 €
CockpitSimParts 20incl~ 12£ 32
PC Flights 276~ 13$ 46

STRATEGIES
To Do:
Shown is the panel as supplied by PC Flights assembled with PC Flights supplied annunciators and toggle 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 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:
    Circuit board for lighting the STANDBY POWER plate. This board will use surface mount LEDs and mount within the acrylic backing panel.
    Circuit board for external connections including for lights, annunciators, and toggle switches.
  • Solder LED's and resistors to LED board.
  • Solder the Connectors to the connector board.
  • Replace the three bolts tying the 2 plates together with longer bolts. Add spacers to these bolts to join to the back connector board.



    Post Script files for the surface mount LED & Connector circuit boards

    LED and Connector
    circuit boards

    LED and Connector
    circuit boards
    Mirrored


    Here is the end result

    Circuit board with LED's and resistors mounted. The parts are not perfectly lined up, but it's what you get when hand-soldering SMD parts.

    The toggle switches are first mounted on the LED circuit board.

    Mount the circuit board and switches to the Standby Power backplate.

    Top view of assembled unit. Note the circuit board and led's between the toggle switches and Standby Power panels.

    Wiring to connector circuit board.

    Rear view




    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