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  1. #1
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    The ugly remote switch

    Have to admit this didnt turn out the way i had imagined!! but should make you laugh..
    This was meant to be used with a quazzle 332 board, as you need two switches..
    biggest problem is finding a small water proof on and off switch that will handle the current draw from the battery..
    In my box of bits i had 2 3amp toggle switches.. and the new ip67 tactile switches..

    looking at this a remote switch for the 333 board should come out nicely as all it needs is the tactile momentary.

    I wont bolt the next one together, ill just use some glue to bond the cover on instead of the bolts!! not sure why i did that in the first place.

    just needs two holes in the side for this one.. for the 333 one hole for a 2 core cable.

    It will probably end up in the bin..i dont like them toggle switches, dont trust them to stay on.



    Last edited by Goldigger; 01-26-2011 at 06:28 AM.

  2. #2
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    The toggle switch facing forward its a safety feature? Auto cut off if you hit something

  3. #3
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    Quote Originally Posted by bravellir
    The toggle switch facing forward its a safety feature? Auto cut off if you hit something
    Yes, it made easier wiring if i had it pointing forwards or backwards.. you can mount the switch the other way round to..

  4. #4
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    Ah Mate, form and function. In the dark you will never see your switch, you'll just be dazzled by how good your light is

  5. #5
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    Nothing to laugh at there! A glued up version could certainly be smaller, but this one puts most other DIY switch housings to shame.

  6. #6
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    Looks good to me GD!!!!!!!!!
    If you wanna se ugly, wait to see what I come up with after my tactile switches arrive from digi key....= )
    Look, whatever happens, don't fight the mountain.

  7. #7
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    Looks Good to me Jay Your making that mill earn its wages .

  8. #8
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    You know Jay you might need to get a production line going and sell the switch to all those who have the Quazzle board. Bit of pocket money to pay for end mills etc

  9. #9
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    There easy enough to machine, delrin is like cutting frozen butter on the mill..
    If I were to make some would people want a bar mounted one or a slimline cable one..
    These ones would be just a single momentary switch to support the 333 boards..

  10. #10
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    Doesn't look ugly to me. I'd be interested in a bar one for a commuter light I'm considering. I fancy a 'dip switch' by the grip that I can press with a thumb to switch high/low.

    If you can make a neat inline version you'll have a ready market on this forum, I'm sure. There are dozens of posts asking where to get them other than Batteryspace.

  11. #11
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    Ok, ill come up with something, do you want the bar mount with the simply oring system?
    how long do you need the wire? 20cm enough?
    Momentary syle switch?
    I need to find some rounnd 2 core as small as possible..

    It will be simular to the one in this thread, but much smaller..no bolts and just the tactile momentary switch..

    Any thoughts?

    Cheers

  12. #12
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    Quote Originally Posted by Goldigger
    Ok, ill come up with something, do you want the bar mount with the simply oring system?
    how long do you need the wire? 20cm enough?
    Momentary syle switch?
    I need to find some rounnd 2 core as small as possible..

    It will be simular to the one in this thread, but much smaller..no bolts and just the tactile momentary switch..

    Any thoughts?

    Cheers
    Cheers Jay

    For me, O-ring mount, 20cm cable and momentary switch would be perfect. Others with wider bars might need a bit more cable, I guess.

    For cable, this is the 3.35mm 2-core I was thinking of using as power cable for a helmet light. Shame they don't sell it by the m. There's enough here for 500 handlebar switches!

    http://www.rapidonline.com/sku.aspx?...catref=02-0260

  13. #13
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    Does anybody know of a glue suitable for bonding delrin to delrin?
    I read that its a difficult material to bond together

    Maybe this loctite super glue will do it?
    http://www.loctiteproducts.com/p/sg_...el-Control.htm

  14. #14
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    How's this for MK2, do you think this is small enough?

  15. #15
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    Quote Originally Posted by Goldigger
    Does anybody know of a glue suitable for bonding delrin to delrin?
    I read that its a difficult material to bond together

    Maybe this loctite super glue will do it?
    http://www.loctiteproducts.com/p/sg_...el-Control.htm
    If you can make the Mk 2 version screwable / unscrewable with let's say mini allen headed screws please mate, then I would certainly be interested in buying a few from you.

    I've just had a remote momentary switch die on me due to pitted contacts, so the ability to replace the switch component without wrecking the housing would be very useful indeed.

  16. #16
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    Quote Originally Posted by Goldigger
    How's this for MK2, do you think this is small enough?
    Looks awesome!!
    Look, whatever happens, don't fight the mountain.

  17. #17
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    Looks spot on to me. I agree that small countersunk screws might be better than gluing, unless that makes manufacture harder

  18. #18
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    Quote Originally Posted by Goldigger
    Does anybody know of a glue suitable for bonding delrin to delrin?
    I read that its a difficult material to bond together

    Maybe this loctite super glue will do it?
    http://www.loctiteproducts.com/p/sg_...el-Control.htm
    I make my switch housings from ABS. Machines quite similarly to Delrin, but is easy to glue. It also bonds better to silicone if you need to seal the cable entry.

  19. #19
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    Only problem with screws is that it will add to the size..
    This is using 1.6mm cap screws with 3mm heads..very tight!
    EDIT...SORRY MADE A MISTAKE IN MY DRAWING..NOT TO BAD WITH THE SCREWS/BOLTS
    FIRST DRAWING AMENDED FOR ERROR
    Last edited by Goldigger; 01-28-2011 at 11:32 AM.

  20. #20
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    Quote Originally Posted by Goldigger
    Does anybody know of a glue suitable for bonding delrin to delrin?
    I read that its a difficult material to bond together

    Maybe this loctite super glue will do it?
    http://www.loctiteproducts.com/p/sg_...el-Control.htm

    I do a lot of work with acetal that is very similar to delrin. I haven't had too much luck gluing parts that have a load on them so mostly I will weld the 2 pieces together with a soldering iron.

    You could try loctite 770 primer to prep the surfaces then use some loctite 406 (Cyanoacrylate). Clamp together in a vice overnight and see haw that goes. You have no load on the parts being glued so it should work.

  21. #21
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    Very tough plastics to bond. Probably not possible. You might try Devcon Plastic Welder. It is a cyano-epoxy. At least it works well for solveable plastics like ABS.

  22. #22
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    I have posted this in another thread.


    Made from a DX keychain light and a silicone cap. Glued to a velcro strap.
    CNC LED light housing for DIY projects

  23. #23
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    Quote Originally Posted by zemike
    I have posted this in another thread.


    Made from a DX keychain light and a silicone cap. Glued to a velcro strap.
    That is an astonishingly good idea!

    I have all the components needed to make one of those.

    Thank you very, very much.

  24. #24
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    After much fettling MK2 has arrived..





  25. #25
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    Looking good. How wide is it?

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