Window Heat 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 Depth6" - 7" (estimated)


Simulator Supplier Parts
Hispa Panels145 x 134 mm
distorted to fit in shorter frame
Sismo Soluciones146 x 152 mm
CockpitSimParts150 x 150 mm
PC Flights146 x 152 mm


December 2016 prices
Supplierpanelannunpartstotalnotes
Hispa Panels 40incl1858 €
Sismo Soluciones-Module 139incl/td>incl139 €Assembled
Sismo Soluciones-Panel 21--------21 €front sub-panel only
Open Cockpits 56incl~ 35 (both panels)91 € (both panels)with Anti-Ice panel
CockpitSimParts 25incl~ 17£ 42
PC Flights 3232~17$ 81
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 WINDOW HEAT 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.
  • Add caps to switch handles (see note below).
  • Solder LED's and resistors to LED board. You may need to use a probe with 12V in series with a 1K resistor to determine the polarity of the LED's prior to soldering.
  • Solder the Connectors to the connector board.
  • Drill and countersink hole in backplate for attachment of the rear connector circuit board.



    Post Script files for the surface mount LED & Connector 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 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 Window Heat backplate.
    NOTE the countersunk bolt.

    Side view of assembled unit. Note the circuit board and led's between the toggle switches and Window Heat panel.
    Wiring to connector circuit board.
    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