Diagram For Optocoupler Combo Board

I made a diagram for the basic layout for the Optocoupler Combo board I whipped up just using some Proto-Board. In the diagram I did not include all of the Optocouplers I'm currently using as it;s likely to change and the format is simple enough to just continue the pattern to add more as needed. I have not added the Digital Compass yet either so I'll be doing another updated diagram later but this gives an idea of how simple it is to connect up some stuff like the Switch Pod button inputs for the Arduino Mega to activate screens in our Knight O.S. Dash Software interface and connect up the LDR and Temperature Sensors. You can see the Optocouplers provide complete isolation between the 12V Switch Pod buttons and the 5V ground pulse needed for the Arduino Triggers.

UPDATE:

I updated the diagram to include the connections for the HMC5883L Digital Compass.

Switch Pods To Sound FX Plan

I found this really cool little Adafruit Audio FX Sound Board WAV/OGG Trigger with 2MB Flash that I figure I could use in conjunction with my Switch Pods to make them play certain sound effects, like for instance if I press the "Turbo Boost" button I should be able to have the sound effect play through either the car's internal speakers or even through the Voice Projection unit loudspeaker mounted into the front nose.

I found this very cool little sound FX board after watching a very cool video by James Bruton of XRobots on YouTube. Check out this cool video and you may begin to see where I am going with this ;)

As you can see from watching the video it's a very easy board to use for props and you can put a lot of sounds on it. The board looks to be small enough to easily stash just about anywhere.

Now one of my concerns was about how the board is powered, for props as you can see it is just a matter of hooking it up to a small battery pack as the board runs off of a 3 - 5 V DC current. Now the car electronics run on a 12V DC Current.... So I remembered that there is a little thing out there called a "Step Down transformer" so I thought to myself;

"OK, before I go and shell out the Frog Skins for this cool little board let me see if there is such a thing as a Step Down Transformer that will convert from 12V DC to 5V DC?"

And guess what? There is! I popped onto Google and did a search and sure enough I found this little gem on eBay for a great price and best of all it's even made to work with the Arduino boards. 

Check out this very cool video that also shows how this Adafruit board can be used.

Mounting Brackets For The Switch Pods

I made a couple of aluminum shaped "L" brackets to be glassed onto the back of the Switch Pods where it gets eventually glassed into place on the Knight Rider Dash. The shape at first glance might look a little odd but when you see the below set of pictures you might see why I made them this shape. It's not that I NEEDED to make them this shape for any real important reason, it's just me being a little "over complicated" I'm sure, I just felt it fit into the available space better and it gave more of a tab to bolt onto the front part of the dash with. I like putting a bit of intricacy into my work whenever possible it somehow makes me feel like I'm doing a more complete job, lol even a lot of times of things no one is EVER going to see. ;)

Right now the mounting tabs I have made are just Contact Cemented into place, I'll let it set overnight and then I can glass then firmly into place tomorrow sometime. This gets me a step closer to getting my Knight Rider Dash done. Once the Switch Pod Switches arrive from Knight Rider World I should be able to start wiring things up under the dash and then I need to pick up a descent Booster Power Pack. The power pack will be a good investment as I can also use it to charge K.I.T.T.s battery should it ever go dead while out and about somewhere where there is no power available. I can also use it to test out the electronics.

Switch Pods Back Access Plates Option

After doing a few test fits with my Switch Pods to the dash I started to notice how close one of the backs of the pods is to the dash itself and I realized that if I ever needed or wanted to get access to the back of the switches wiring and boards it would be very tight in there to get a screwdriver to take the access plates off. So I'm wondering if maybe I should make those access plates attach on with Velcro tabs? I have short screwdrivers but I'm not sure if they are short enough to be able to get that one access plate's screws out. As is what I would have to do is take totally out one of the dash consoles circuit boards, overlay and Lexan plastic cover just to be able to get a screwdriver back there. So another method of attaching those access plates might well be worth looking into. I'll keep you posted on what I finally decide to do for this potential issue.

Switch Pod Back Access Plates Added

The backs of the Switch Pods have been glassed in and sanded down flat. I was not too concerned about the middle as that part is getting cut out anyways to allow access to the back of the Switches Circuit Boards and wiring.

I made a template out of some thin card stock I had kicking around and traced out two guide lines, the inner line indicates where I will cut out the back of the Pods. The outer line indicates where my aluminum cover plates will rest.

Using the good O'l trusty Dremel tool with a cutting wheel I cut out my access holes on both sides of the Pods. Next I made the aluminum cover plates. I made 4 holes in my card stock template to mark where the screw holes would need to be drilled. Once cut out and drilled the aluminum cover plates were screwed onto the back of the Pod access ports with some short self tapping screws being careful not to over tighten the screws. The aluminum cover plates are secured to the back of the pods very securely. Eventually they will be painted. I will most likely also contact cement onto the back of each cover plate a thin piece of thin high density foam rubber to act as an additional insulation barrier.

Now basically all that's needed is the switches for the Pods, then I can install those. I'll need those before I can cut out the front of the pods for the switches just so as I know what size to cut out my rectangular holes. Then another test fitting off the dash will be in order so I can best determine how my Switch Pods assembly can be glassed onto the 2 TV Dash.

Glassing in The Backs Of The Switch Pods

I have begun the task of glassing in the backs of the Switch Pods using those plastic backs I made and fibre glassing over top of them, basically glassing them securely to the backs of the pods. The stuff sets pretty quick so I've been doing it in small one ounce batches and brushing in my fibre glass matting. It's starting to look pretty good. Soon I'll be able to file and sand it all down and then cut out the access holes at the back that I'll make aluminum access plates for as mentioned in my last post.

Here is a closeup shot of one side of my Switch Pods back in the process of being glassed in. This way you can see how I am going about doing this.

There are some out there I know that think this is a crappy Switch pod, but it's REALLY not! Now this is just my opinion of course but if you like a bit of "Do-It-Yourself" (And who Doesn't) and you are like me pretty crafty and innovative then this pod is perfect for the "Do-It-Yourselfer." 

There are some that think I went a little overboard with the aluminum reinforcing to my Pods as well. But to me knowing that damage can result by accidentally bumping your knee's into the Pods as I have heard some had issues with then to me what is a little foresight into that and taking steps to help prevent that type of potential damage from occurring... again "Just My Opinion" not saying "Go Do It" or anything.... it's just an extra step I feel I should do and would be more comfortable knowing I had done. 

I'll pretty much do the same type of "Over the Top" reinforcing when I get around to glassing the Switch Pods to the 2 TV Dash. Hey this is an expensive hobby and I feel that extra mile is worth going, especially if it helps prevent potential expensive repairs later on. ;)

Making The Backs Of Switch Pods

With me getting a lot closer to being able to install the dash or at the very least do a few more test fittings as I get things ready I figured that I better get the lead out on working on my Switch Pods. I placed an aluminium support inside the back of the Switch Pods because I had heard that some people had problems accidentally breaking their pods by banging their knees against them whilst getting in and out of the car. So this is just one of those little extra steps that I'm hoping will prevent that from happening by making the pods a lot more stronger by giving them some additional internal support. I have also placed in 4 pieces of aluminum pipe 2 each side to act as wire conduits for the switches. I probably didn't really need to but I figure it's just another way to help keep wires neatly bundled together and help prevent any possibilities of dangling loose wires.

I have also used some more of that plastic I salvaged from an abandoned T.V. set's casing to make back cover plates for the Switch Pods. I will glass over these and eventually cut out an access panel on the back to allow access to the backs of the switches circuit boards. What I'll do is make an aluminum cover plate that can then be screwed onto the back that way there is no danger of accidentally coming into contact with the backs of the circuit boards or and debris to fall back into the pods and cause shorts or damage to the switches circuit boards.

Here you can see a view of the back of the Switch Pods with my plastic covers just resting in place for now until I am ready to glass over them. Once that is done I'll be able to cut out the access holes for each side of the Pods and then make my aluminum access plates. I'll keep you all posted on how that goes once I am at that stage. Next will be to glass my Pods to the Knight Rider 2 TV dash.

Reinforcing the Switchpods

I'm not entirely sure if it is a necessary job or not but after hearing a few stories on how the switch pods tend to get in the way of your knees from time to time and with that possibly being an open invitation to getting them damaged I thought of perhaps reinforcing them with some thick pieces of aluminum. I picked up some stock aluminum and this is what I came up with. I will glass thus into place and that should add a significant amount more sturdiness to the switch pods along the bottom where they are in possible danger of being constantly bumped with my knees getting in and out of K.I.T.T.