The work on the Rear Logic Display went well this weekend.
Here is the Cad Drawings I made to Get all the parts to fit in this little space.
First up was the Creation on the Bezel. This piece is used to Line up all the 3mm Leds so they look neat and are easier to see.
I've tried to make this out of styrene previously and the drill bit ripped the lattice out (but only after I drilled 80-90 holes ...there's 108 total)
So this time I'm using a 2.5mm thick Aluminum plate...The Lattice shouldn't tear as easily.
I printed the Bezel layout 1:1 then coated the back in a thin layer of spray adhesive ( this keeps the print from moving on you when your marking the centers to drill). Once the layout was in place I used a scratch all the mark dead center for each hole, next I center punched each hole. Here's what it looked like when that was finished.
If you look at the bottom of the plate you can see my first set of mistakes. I used a 1/8" drill bit to bore the holes, and it ended up cutting through the lattice. To fix the problem I got a smaller drill bit but will have to file out each hole a bit to let the 3mm LEDs fit in them....Snuggly! (if you look a the center of the mistake area you'll see these test holes...Works great! After allot of hole drilling, and some shaping the bezel looks great.
I also worked on etching the circuit board that the LED's will be hooked to.
As with the bezel I printed the layout out 1:1 on a Laser printer. Then cut it to fit the board. I also added alignment marks (not shown in the Drawing here) so both sides of the PCB (printed Cuircut Board) line up. I drilled 0.004" holes in the center of these marks and put pins in them. Then I Laid the Layouts printed side to copper on the board and heated with my iron for abit (20-30mins total) watching all the time not to burn the paper. Once that was complete I soaked the paper off in water. This is what it looked like after the water bath. (sorry just realized that I have no pics of that Process prior to this...I'll get them up the next time ..as I have many more PCBs to make for R2)
Now the board gets soaked in ferric chloride till all the unwanted copper is gone. Rinse the board with water and your ready to drill.
Here is the PCB and the Aluminum Bezel side by side.
Here a couple of pics showing the way these parts will be used together.
The first is the Rear Logic surround (made from Resin) with the Aluminum bezel underneath. The Second shows the PCB with the Bezel over it underneath the RLS.
Now I have to finish Drilling the 200+ 0.004 holes in the circuit board (got some drilled but broke my bit and it was late so I went to bed) and Solder in 108 Leds (thatís 216 Solder joins just for the LEDS!) I'll post those pics in a few weeks. Ha it takes time to do all that work, plus I've got some other parts that I need to get done quick before I do all the tedious stuff.
Let Me know what you think.