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Custom Autopilot Panel (Read 4124 times)
Mar 8th, 2008 at 5:10pm

BTilson   Offline
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Tell me what you think about this... I am definitely not going for a replica of any "real" AP panel, but instead more for a functional generic panel for a basic GA autopilot. I generally prefer the low and slow flying of a basic 172, so this panel should suit me from now on. (Theoretically)

Anyway, here is the screen shot, designed with Front Panel Designer (link available on this forum)

This will be made from 2mm anodized black aluminum stock, professionally CNC machined. Dimensions are 6" x 3". Price for this panel: $47.37.

Not too bad if you ask me.

...
 

The first step on the long journey of building a flight simulator has been taken... There is no turning back now!
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Reply #1 - Mar 8th, 2008 at 5:15pm

RitterKreuz   Offline
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i like it  Wink
 
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Reply #2 - Mar 8th, 2008 at 5:42pm

JSpahn   Offline
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sweet Wink no turning back now Grin Grin
 

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Reply #3 - Mar 8th, 2008 at 8:38pm

JBaymore   Offline
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BTilson,

Glad you found that Frontpanel Designer link I posted.  Looks good.  Real metal is nice....pricey but nice.  Are you sure about the 2mm?  That is THIN.  It'll have to have a backing plate.

Well... you are on your way to bankruptcy and depravity.  Wink

best,

..................john

 

... ...Intel i7 960 quad 3.2G LGA 1366, Asus P6X58D Premium, 750W Corsair, 6 gig 1600 DDR3, Spinpoint 1TB 7200 HD, Caviar 500G 7200 HD, GTX275 1280M,  Logitec Z640, Win7 Pro 64b, CH Products yoke, pedals + throttle quad, simpit
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Reply #4 - Mar 8th, 2008 at 11:19pm

BTilson   Offline
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Actually 2mm was a rather arbitrary choice now that you mention it. I'm glad you brought that to my attention. Increasing thickness should contribute a good deal to stability, and only shoots price up marginally. I intend to use this with the joystick I ripped apart. I've already got all my momentaries wired up to the joystick PCB and have tested it out completely, and it's all still functional. All those pretty buttons just need a home now, so I figured the first logical step for me would be to building something that a) I could fully support with the built in FS controls and b) that I used a lot. The natural choice was a generic autopilot panel. I do suppose that I shall eventually upgrade to one of the GoFlight modules or something similar, but I think this should do me just fine for a long time to come.
 

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Reply #5 - Mar 11th, 2008 at 9:14am

BTilson   Offline
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Update!

I discovered that you can do a true to scale print out from the panel designer program, so my first thought was PROTOTYPE! I cut out a piece of plexiglass the appropriate size, then marked all the holes and such. I then drilled them all out with my drill press and used my sons glue stick to just glue the printout to the back of it. I cut out the switch holes in the paper with scissors. I then put in all my switches and tightened them all down. It doesn't LOOK very pretty, being a (rather poorly) printed panel backing a piece of rather beat up plexiglass.

BUT... it WORKS. Only thing left to do is program a macro for the AP altitude + and - adjustments since those aren't available in default FS controls. I still need to build an enclosure so there are a bunch of wires all over my desk at the moment, but it WORKS. I have built my first piece of real sim hardware! A fully functional AP panel.

It's amazing just how much more immersive it makes everything feel just by that one little addition. Now to engage any of the AP modes, or to adjust my heading bug, I can just use the panel I made. No more mouse clicky clicky for me. (At least not for AP functions!  Cheesy)

I spent a couple of hours just doing touch and gos around one of my favorite little airports, playing with the AP heading and approach modes and such. It was very fun. (Runway 3 at KMRN if anyone is interested in checking it out. Has a localizer approach, but no glideslope. GS help is a VASI by the runway) I'd shoot one landing with approach mode on and just control the slope, land, take off again and circle around, then shoot the next approach completely by hand. It was a blast.

I don't have any pictures of the "finished" panel yet, but I shall take some this evening and update again.

On a side note, I had my first experience in a REAL plane on Sunday. Went to the local regional airport (KAVL, Asheville Regional) and took a "Discovery Flight" with WNC Aviation. Went up in a Cessna 172SP. It was an ABSOLUTE BLAST. I actually got to handle the controls a bit and everything. It was well worth the $100 fee for the flight.
 

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Reply #6 - Mar 12th, 2008 at 1:48am

gokhotit   Offline
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I am also creating a custom autopilot panel, using light up korry style switches (which I got for free Cool), and othe various light up annunciators and switches.  Its still a work in progress as far as the layout, and the labels will not be on the panel but on the switches.  Let me know what you think.

...

 

The Sim Console..."outside the box", within a box http://i168.photobucket.com/albums/u185/gokhotit/th_sim.jpg
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Reply #7 - Mar 12th, 2008 at 6:58am

BTilson   Offline
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I like that very much, a very cool layout. Are the drilled holes going to be for encoders? I am guessing so since they're under the buttons that have an adjustable value (CRS, HDG, ALT)

If you are going with encoders, what kind are you planning on using?
 

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Reply #8 - Mar 12th, 2008 at 9:35am

gokhotit   Offline
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I havent gotten that far as far as deciding which encoder to use, and yes the drilled holes are for encoders.
 

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Reply #9 - Mar 12th, 2008 at 11:37pm

JSpahn   Offline
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any 2 bit "grey scale" encoder should work fine Wink
 

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Reply #10 - Mar 14th, 2008 at 12:23am

gokhotit   Offline
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will potentiometers work?
 

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Reply #11 - Mar 14th, 2008 at 7:48am

JSpahn   Offline
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for the altitude, vert speed, heading, and nav a pot isnt what you need. Encoders send momentary key pulses and allow you an unlimited range. Pots basically offer a set range of resistance example 100k ohm is 0-100k ohms of resistance as you move the dial.

To be honest I dont think you can setup a pot for that application. If you are looking for an encoder opencockpits has them Wink
 

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Reply #12 - Mar 20th, 2008 at 1:18am

gokhotit   Offline
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actually a pot will work.  I took one of my mixture levers (a slider pot) and configured it for the autopilot altitude selection.  Works like a charm from 0 to 49688 feet.
 

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Reply #13 - Mar 20th, 2008 at 6:57am

JSpahn   Offline
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cool Wink
 

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Reply #14 - Mar 20th, 2008 at 6:59am

BTilson   Offline
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Care to elaborate on how you did that exactly? Did you do it through FSUIPC or something similar or did you use default FS controls somehow? I have a bunch of pots at home wired up but not currently in use, and I would like to assign one of them to the AP altitude thing like you mentioned.

I guess it is also relevant, what FS do you use? FS9/FSX?
 

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Reply #15 - Mar 20th, 2008 at 6:18pm

gokhotit   Offline
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I use phidgets for my interface, so FS2PHIDGET is used as well.  I have the mixture controls hooked up to slider pots (see my sig for details), I just reassigned the handle to offset 07D4 (autopilot altitude).  just moved the pot and there it is.  works like a charm, a little bit on the sensitive side (small altitude changes are hard to do).  Assuming all is the same I don't see any reason why it sould not work with any other offset.
 

The Sim Console..."outside the box", within a box http://i168.photobucket.com/albums/u185/gokhotit/th_sim.jpg
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Reply #16 - Mar 28th, 2008 at 6:13pm

gokhotit   Offline
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I ordered my panel from frontpaneldesigner.  Will be here around APR 12.  Will post a pic when it gets here..hope it is as good a quality as everyone is saying.. Tongue
 

The Sim Console..."outside the box", within a box http://i168.photobucket.com/albums/u185/gokhotit/th_sim.jpg
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Reply #17 - Mar 29th, 2008 at 2:18pm

BTilson   Offline
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Hey good. I look forward to seeing what kind of work they do. Please post some nice up close detail shots as well. It will be nice to see a customers panel up close, instead of the "examples" on the web site.
 

The first step on the long journey of building a flight simulator has been taken... There is no turning back now!
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Reply #18 - Mar 29th, 2008 at 8:33pm

JBaymore   Offline
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BTilson wrote on Mar 29th, 2008 at 2:18pm:
Hey good. I look forward to seeing what kind of work they do. Please post some nice up close detail shots as well. It will be nice to see a customers panel up close, instead of the "examples" on the web site.


I agree completely.  Thinking of using them for some stuff. 

best,

.................john
 

... ...Intel i7 960 quad 3.2G LGA 1366, Asus P6X58D Premium, 750W Corsair, 6 gig 1600 DDR3, Spinpoint 1TB 7200 HD, Caviar 500G 7200 HD, GTX275 1280M,  Logitec Z640, Win7 Pro 64b, CH Products yoke, pedals + throttle quad, simpit
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Reply #19 - Mar 30th, 2008 at 9:53pm

gokhotit   Offline
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oh good...Im the guinea pig.. Cheesy
 

The Sim Console..."outside the box", within a box http://i168.photobucket.com/albums/u185/gokhotit/th_sim.jpg
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Reply #20 - Apr 5th, 2008 at 12:23am

gokhotit   Offline
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Well, my panel came in today, and it looks GOOD>> Cool.  However, the lesson learned is "measure twice".  I got a little rework to do, but it is my fault, not theres.

here is how it came, and yes the gummy bears came with it. Grin
...

here is the backside coating.  I inspect this stuff for a living and I approve it.
...
 

The Sim Console..."outside the box", within a box http://i168.photobucket.com/albums/u185/gokhotit/th_sim.jpg
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Reply #21 - Apr 5th, 2008 at 2:07pm

BTilson   Offline
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Looks like they do pretty clean work! I work in steel manufacturing myself, so the questions that come to mind for me, is there any burring anywhere? Are all the edges broken and smooth, or did they leave them at raw sharp corners?
 

The first step on the long journey of building a flight simulator has been taken... There is no turning back now!
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Reply #22 - Apr 5th, 2008 at 5:57pm

gokhotit   Offline
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all the edges are smooth and sharp, and the engraving is clean and straight.  VERY GOOD WORK, I would use them again.
 

The Sim Console..."outside the box", within a box http://i168.photobucket.com/albums/u185/gokhotit/th_sim.jpg
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Reply #23 - Apr 11th, 2008 at 11:32pm

gokhotit   Offline
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TO BTilson, I am sorry if i hijcked your thread, but I figures it would fit here Embarrassed

i have an update on my panel.
Got the switches in place and the push buttons wired.    Cool

front side
...

Back side
...
good thing I color code...let me know what you think.

sorry about the poor lighting

EDIT:  the labels currently on the switches will be changed when I am done.
 

The Sim Console..."outside the box", within a box http://i168.photobucket.com/albums/u185/gokhotit/th_sim.jpg
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Reply #24 - Apr 12th, 2008 at 5:04am

BTilson   Offline
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Hey, no prob on the hijacking. You're the one who has the actual panel made, which looks very nice by the way.
 

The first step on the long journey of building a flight simulator has been taken... There is no turning back now!
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Reply #25 - Jun 6th, 2008 at 1:24am

gokhotit   Offline
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got the power wired up.  Just a small update, havent worked on it for awhile.  

...

PS red is lights, white is switch power
 

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Reply #26 - Jun 6th, 2008 at 9:59am

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Very nice; what do they charge for one of these one-offs?

 

...
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Reply #27 - Jun 6th, 2008 at 8:15pm

gokhotit   Offline
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I dont know how much "they" would charge.  I have about $150 invested in it (switches were free, and the I/O card that will be on it is a spare).
 

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Reply #28 - Jun 7th, 2008 at 7:45pm

gokhotit   Offline
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I have run into a snag Embarrassed.  I get the panel powered up, got 35v output  (phidgets handle a max output of 30v)  on one light, ok, no problem just add a resistor and be done with it.  Problem is,  the more lights I turn on the more it loads and the lower my voltage goes.  I need a variable type of resistor that adjusts itself to maintain 28-30v no matte what the load is.

I know that people will say "change the i/o card""buy a new power supply", etc.  i dont have a lot of money to get stuff like that, I am trying to do this as cheaply as possible. 

What I am asking,  is if anyone has any ideas how I can control current cheaply?
 

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Reply #29 - Jun 7th, 2008 at 9:24pm

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gokhotit, if you could describe your wiring in a bit more detail it should be possible to help you...

I have two questions off the top of my head..

1. Why are you using 30 volts?
2. What are you using for a power supply?
 

Steve (Silver Fox) Daly
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Reply #30 - Jun 7th, 2008 at 11:26pm

gokhotit   Offline
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Actually it is 40v, all I had on hand.  All the power is bussed in parralel.  30v is the magic number because that is the max that the IO card can take.
 

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Reply #31 - Jun 8th, 2008 at 1:08am

SilverFox441   Offline
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What are the specs on the power supply.? It might be 40V, but if it can't handle any current it's not going to be much use to you.

I think you might be better off modding an old computer power supply to get useable voltages and currents. Probably cheaper in the long run as well.

Check out this thread: http://www.simviation.com/cgi-bin/yabb2/YaBB.pl?num=1177366444/0#0
 

Steve (Silver Fox) Daly
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Reply #32 - Jun 8th, 2008 at 2:47pm

gokhotit   Offline
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It is a ac-dc adapter rated at 30v at 500mA, however it puts out 37-40v.  I have considered a modded comp power supply (thats what powers my main console), however it will be about $150 in just light bulbs to re-bulb everything.
 

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Reply #33 - Jun 8th, 2008 at 7:44pm

SilverFox441   Offline
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That adapter isn't going to do you any good at all... 500mA is hardly any current.

Take a look at the specs on an average 350W power supply:
http://www.ultraproducts.com/product_details.php?cPath=103&pPath=653&productID=6...

What light bulbs are you using that require 30 volts?
 

Steve (Silver Fox) Daly
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Reply #34 - Jun 8th, 2008 at 9:13pm

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gokhotit,

I'd use LEDs rather than bulbs,  with LEDs you don't need a wopping great PS as LED power consumption is very small compared to a bulb, and they're cheap !!

Regards,
.............Adrian W.
 
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Reply #35 - Jun 9th, 2008 at 11:07am

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gokhotit wrote on Jun 6th, 2008 at 8:15pm:
I dont know how much "they" would charge.  I have about $150 invested in it (switches were free, and the I/O card that will be on it is a spare).


By "they" I meant the shop that cut the panel for you.
 

...
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Reply #36 - Jun 9th, 2008 at 6:46pm

gokhotit   Offline
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The panel cost about $40 from Front Panel Express.  Really good quality, just make sure you measure twice Tongue so you don't have to do any rework.

The switches are Milspec Aircraft switches, so they have aviation 28V bulbs in them.  Putting LEDs inside these switch housings will destroy the housing themselves, due to the way they are laid out.

If anyone knows where I can get 12v T-1 3/4 midget flange, and super tiny sub-midget flange bulbs for cheap, that would help.  Then I can run the whole thing off my main power supply (500W PSU).

So, the battle continues.. Undecided
 

The Sim Console..."outside the box", within a box http://i168.photobucket.com/albums/u185/gokhotit/th_sim.jpg
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Reply #37 - Jun 9th, 2008 at 8:27pm

SilverFox441   Offline
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What's the bulb number for the ones installed in the switches?

It may be possible to get conversion bulbs for 12V or even LEDS that just drop in.

Maybe even this page?

http://www.ledtronics.com/ds/FF200/
 

Steve (Silver Fox) Daly
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Reply #38 - Jun 9th, 2008 at 11:02pm

gokhotit   Offline
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Those are perfect, but i need the blue and they are WAY WAY WAY out of my budget.  But I love it. Cheesy
 

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Reply #39 - Jun 9th, 2008 at 11:08pm

gokhotit   Offline
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Just for fun, I put in an order (just in shopping cart), and it would be $400 in bulbs Huh.  Don't think the wife will let me get awa with that.
 

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Reply #40 - Jun 10th, 2008 at 1:53am

SilverFox441   Offline
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http://www.1000bulbs.com/337-to--394-Indicator-Lamps/
382s what you need? Those are a drop-in replacement for the typical 387 28V indicator lamp.

 

Steve (Silver Fox) Daly
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Reply #41 - Jun 10th, 2008 at 2:31pm

gokhotit   Offline
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Those will work, or the 394s.  It's so close to being done I am getting jittery Shocked.  I am hoping to have it functional within the next two weeks.  Cheesy
 

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Reply #42 - Jun 11th, 2008 at 1:54am

gokhotit   Offline
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Hooked up the pots to my card.  Works liek charm... Cool Cheesy  Shocked
 

The Sim Console..."outside the box", within a box http://i168.photobucket.com/albums/u185/gokhotit/th_sim.jpg
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Reply #43 - Jun 22nd, 2008 at 2:03am

gokhotit   Offline
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got the switches and everything all hooked up.  The phidgets card is defective Embarrassed.  However, all the buttons do work, and all the lights work, just can't program it (says my 0/16/16 is a 0/64/64, I wish).

So, the quest continues.....

Anyone got a spare 0/16/16 phidget card they want to let go for cheap?? Wink
 

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Reply #44 - Jun 24th, 2008 at 7:02pm

gokhotit   Offline
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here is a picture of the completed wiring (with bad board in place)  and temporary labeling.  What do you think?

...

...
 

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