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Posts Tagged ‘build’

LED Torch (flashlight) Conversion – Build

December 3, 2010 1 comment


Ok, so i designed my torch. This is fine but designs are no good unless you actually put them into practice. This is quite a quick build that goes together nice and quickly and has some nice satisfactory results:

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DIY Bench Supply Summary

November 30, 2010 1 comment


I’ve updated my bench power supply project description with a summary of the project (as follows):

Project Summary

This project started as me trying to fulfil a need for a reliable and convenient power supply and wanting to learn some lessons along the way. I designed the project in sketchup and then proceeded to go through various stages of construction. There were a few design changes along the way but nothing major. I decided to add an external voltage probe and a switch to allow voltage measurements either from the ammeter or ground.

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Power Supply – Case Completion

November 26, 2010 13 comments


I’ve finished most of the construction and i decided that this project has taken longer than i’d hoped. I wanted to finish it so here is the final build and assembly in one huge post.

Parts Used:

  • My Adjustable Voltage Circuit
  • My Panel Meter Circuit
  • My Aluminium Supply Case (Labelled)
  • 2x DPDT switch
  • Green Binding Post
  • 4x Red Binding Post
  • 4x Black Binding Post
  • 3mm Red LED
  • 6x 3mm Green LED
  • 7x 3mm LED panel clips
  • 4P2T rotary switch
  • Amp Panel Meter
  • Voltage Panel Meter
  • Red Multimeter Lead
  • 2x 6mm knobs
  • ~20cm of 3mm 3:1 Heatshrink
  • 2x TO-220 heasinks
  • ~50 Crimp terminals
  • Lead Free Solder
  • 3x 47 KΩ resistors
  • 3x 5.6 KΩ resistors
  • 3.9 KΩ resistor
  • 820 Ω resistor
  • 12 KΩ resistor
  • 1.8 KΩ resistor

Tools Used:

  • Soldering Iron
  • Crimping tool
  • Snipe nosed pliers
  • Wire cutters
  • Glue Gun
  • Phillips screwdriver
  • 2mm Allen key

For most of this it should be clear how it goes together. The circuit construction just followed my power supply schematic. If there is anything that needs explaining further then feel free to ask. Unfortunately i got a bit carried away at some parts and forgot to take photos, I’m still learning to take my time.

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Aluminium case finishing

November 10, 2010 4 comments

The power supply is coming along nicely. The case is built but needs some improvements and finishing touches. I plan on using this supply for some time and so want it to look as tidy as possible. I finished the case by routing the cables and putting labels in appropriate places.

Parts Used:

  • Dry transfer lettering (Letraset)
  • Permanent marker (Sharpie)
  • Clear Coat spray

Tools Used:

  • Pillar drill
  • 4mm drill bit
  • 8mm drill bit
  • 12mm drill bit
  • G-clamp
  • Ruler
  • Disposable gloves
  • PCB cleaner (citrus degreaser)
  • Craft knife

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Aluminium case construction

September 24, 2010 2 comments

or aluminum if you prefer.

This has taken a while to put together as I don’t have any power tools of my own, so I’ve been borrowing others.

Parts Used:

  • Aluminium Sheet – 0.5mm x 500mm x 500mm
  • Two part epoxy glue (Amazon, uk)

Tools Used:

  • Ruler
  • Permanent marker
  • Aviation snips (Amazon, uk)
  • Dremel 300 (Amazon, uk)
  • Dremel SpeedClic cutting disk (Amazon, uk)
  • 2x square edged wood planks
  • square edged desk
  • G-clamp
  • Pillar Drill
  • 4mm drill bit
  • 5mm drill bit
  • 8mm drill bit
  • 10mm drill bit
  • rat tail file (round file)
  • de-burring tool (Amazon, uk)

I started with a big sheet of 0.5mm thick aluminium. I had already decided on the layout of the components on the front so it was just a case of drawing it on the aluminium and cutting it out.

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Power Supply Design

July 26, 2010 5 comments

I’m starting out with a highly useful project.

Realising that i need a decent power supply for my projects, and a place to work from, I looked at getting myself a bench top power supply, but at £100+ for a decent one, I looked into building one and came across this instructable. It looks like i can build one for less than the cost of buying and it should give me more output options and more current. Since the whole point of this adventure is to start building stuff from scratch too, it makes sense to make it myself.

The principle looks fairly simple and the only circuits required seem quite basic so i jumped in and started ordering parts.

While i was waiting for parts, i set about designing my new power supply in google sketchup (free):


(download .skp file)

The power supply is based on an old pc ATX power supply. This is great because they are cheap, efficient and provide a huge amount of current on demand. I didn’t have any spare power supplies lying around so i asked a few friends and managed to get a nice 550w supply for free. This has a huge 12cm fan on top which will be useful for cooling my electronics as well as the supply itself.

The supply has a bundle of wires coming from it. All wires of the same colour provide the same function and so can be bundled together.
the voltages provided are:
-12v: blue wire
3.3v: orange wire
5v: red wire
12v yellow wire
as usual the black wires are ground
There are a number of other wires coming from the supply and these have special functions that i’ll explain later. If you’re curious you can look at the wikipedia page

in addition to these outputs I’m adding a variable output by using a variable low drop out, linear voltage regulator on the 12v line. This should give me from 1.4v to 11.6v with a couple of amps.

ATX power supplies have had a number of revisions and some older ones include a -5v output on a white wire. Unfortunately this one doesn’t but I don’t think I’ll miss it much.

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