Cockpit Voice Recorder Switch Panel

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

Backplate
Width5.75" (approx 146.05 mm)
Height4 DZUS units (4 x 0.375")
1.5" (approx 38.1 mm)
Backplate Thickness1/16"
Light Plate Thickness1/4" (0.25")
Module Depth?????????????????????????????


Simulator Supplier Parts
Hispa Panelswith Air Conditioner Panel
Sismo Solucionesdimension not listed
CockpitSimPartspanel not found


December 2016 prices
Supplierpanelmeterannunpartsknobstotalnotes
Hispa Panels 4014incl14~ 2492 € (total both panels)with Air Condition panel
Sismo Soluciones-Module 49incl49 €Assembled
Sismo Soluciones-Panel 17----17 €Panel only
Open Cockpits Panel Not Found
CockpitSimParts Panel Not Found
PC Flights 21------3---$ 24

STRATEGIES
To Do:
Shown is the panel as supplied by PC Flights assembled with PC Flights supplied toggle switche.
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 2 DZUS replica bolts (PC Flights and Sismo both supply them).
  • Fabricate 1 new circuit board:
    Circuit board for lighting the voice-rec-sw panel. This board will use surface mount LEDs and mount within the acrylic backing panel. This board also has connectors for the toggle switch.
  • Add caps to switch handle (see note below).
  • Solder LED's and resistors to LED board.
  • Solder the Connectors to this same board.
  • Drill 2 holes in the circuit board to clear the 2 front panel screws.



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

    LED and Connector
    circuit board

    LED and Connector
    circuit board
    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.

    Mount the circuit board and switch to the voice-rec-sw backplate.

    Top view of assembled unit. Note the circuit board and led's between the toggle switch and voice-rec-sw panels.

    Rear view


    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