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Author Topic: Nut-less switch mount  (Read 1572 times)

Offline Warren Wagner

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Nut-less switch mount
« on: September 18, 2010, 09:42:23 AM »
Hi gang,

It's very convenient to use the mounting nut that come with small switches, but they can make the outside of your plane look less than attractive.   I was scratching my head, trying to find a way to mount the switch without having the nut on the outside of the fuselage.

This is what I finally came up with.

Photo 1  -   A small block was fabricated out of soft pine.   The hole was a light press  fit over the switch body, and the block required a slot for the two wires to be fished through.

Photo 2 -  Because it was impossible to drive a mounting screw for the block horizontally,  I simply pressed the block tightly against the switch, and drove the screw vertically through the "tank" floor.

Photo 3 - An this is what it looks like from the outside when you are all through.   Cutting a hole through the Ultracote was done with a piece of sharpened brass tubing in order to get a clean cut.  Actually, the tubing was used to cut through the balsa and plywood as well.

It was a little extra effort, but the resulting clean appearance was worth the trouble.

Cheers.

Warren Wagner
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Offline Crist Rigotti

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Re: Nut-less switch mount
« Reply #1 on: September 18, 2010, 12:46:48 PM »
Elegant solution Warren.  I would expect nothing less from a craftsman like you.
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Offline TDM

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Re: Nut-less switch mount
« Reply #2 on: September 18, 2010, 02:34:28 PM »
Why did you stop there?  ??? ??? ??? ??? What about the safety plug?  :! :! I believe it feels left out just about now. mw~ mw~ mw~
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Offline Rudy Taube

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Re: Nut-less switch mount
« Reply #3 on: September 18, 2010, 04:55:14 PM »
Hi Warren,

What Crist said!  y1

I agree with Traian. Your idea would make your (our?) safety plug look as cool as your start button.  8)

Your post is perfect timing, I'm installing my E system in my new SV-11 ARC this week. I plan on using your idea, thanks.  :!

Regards,  H^^
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Offline Dennis Adamisin

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Re: Nut-less switch mount
« Reply #4 on: September 18, 2010, 08:23:51 PM »
Show-Off!!!!   8)  ;D  ;)  BW@ CLP**

That is a really nice installation - thanks for sharing...
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Offline Warren Wagner

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Re: Nut-less switch mount
« Reply #5 on: September 19, 2010, 07:46:13 AM »
Quote from: Traian Dorin Morosanu on September 18, 2010, 02:34:28 PM
Why did you stop there?  ??? ??? ??? ??? What about the safety plug?  :! :! I believe it feels left out just about now. mw~ mw~ mw~

Thanks, guys.  I appreciate the positive comments.

Traian....you are a tough audience to satisfy!   :)  Just kidding.   Actually, I worked on a "blind" mount for the arming switch for quite a while before I threw in the towel, and decided I was wasting too much time, and just just went ahead and mounted it on the outside.  (I knew somebody would catch me !  )    :)  

A small mounting plate was made, with blind nuts recessed into the back side.  My thought was to glue this plate to the plywood fuselage doubler, and then just cut a hole through the fuselage for the arming plug to be inserted.

The plan for the electrical installation, was to locate everything, as much as possible, low (while working with the plane upside down) in the "tank" compartment so as to make battery exchanges convenient .  This caused an impossible task of trying to tighten horizontal bolts, even Allen cap screws with a ball driver,  in a narrow space.  

In hindsight (I have lots of that),  a soft pine block could have been made that would mount both the "start" switch and the arming plug, and be secured with two screws, one on each end of the block, going into the "tank floor", just like the starting switch mount.    So Rudy, you can try that on your SV-11 and see how it works.  Post a photo when you're done.

So, today the "e-Rex" is finally done, and they predict rain showers for the Syracuse area.   Ain't that the way it always goes !     Being retired gives me the option of going anyday this week when the weather is sunny and warm.    "Such a deal !"

Cheers.

Warren Wagner
  [/u]
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Offline TDM

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Re: Nut-less switch mount
« Reply #6 on: September 20, 2010, 12:24:41 PM »
What do you think about this concept safety switch.

I works by opening the hatch and depress it from the inside after you insert the battery or remove it. Then on the flight line you press it in to connect the battery. The two side components are spring loaded and the wire is placed in with set screws. You can see the mode of operation from the side detail and the assembly shows a 1/8 balsa sides and 1/16 doublers. It will work with 1/32 doublers too. The button is made from aluminum and Delrin, color red for aluminum and color blue for the Delrin, as you can tell one position isolates while the other connects.
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Offline Wynn Robins

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Re: Nut-less switch mount
« Reply #7 on: September 20, 2010, 04:38:18 PM »
not sure if I understand correctly - but if you have to push the button from the inside to disconnect the circuit - then at the end of the flight (when you need to ARM the safety switch again) it seems like it would be a pain in the butt...

it needs to work both before AND after your flight to isolate the battery quickly

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Offline Mike Scholtes

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Re: Nut-less switch mount
« Reply #8 on: September 20, 2010, 06:29:38 PM »
Warren, as long as you're at it, how about a shot of your battery retention system, which I see lurking in the background. I am about to start the component installation in my new ARF Legacy (I will post pix) and would like to see what others have done. I'll bet Rudy has some good ideas too. Thanks in advance.
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Offline Rudy Taube

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Re: Nut-less switch mount
« Reply #9 on: September 20, 2010, 10:31:07 PM »
Hi Mike,

You may want to look at how a Master Builder mounts his battery. Just go down about 23 posts to see my thread asking about front mounted motors. Bob Hunt posted several excellent photos on his install. The rear part of his battery mount just slides into a slot in a rear bulkhead. The front is held by a nylon bolt, the photo shows a metal nut, but Bob has now replaced this with a nylon wing nut, making it lighter and "tool-less" to use. :-) ....... Since my 1st contact with Velcro decades ago (in a bedroom environment) I have fallen in love with this cool invention. I use it all over my boat and everywhere else I can, including mounting of our batteries. But after seeing Bob's KIS system I may try it. It is light, easy to make, provides max cooling, safe, and looks foolproof.  :!
« Last Edit: September 21, 2010, 12:55:38 AM by Rudy Taube »
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Offline Rudy Taube

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Re: Nut-less switch mount
« Reply #10 on: September 20, 2010, 10:58:51 PM »
Hi Traian,

That is a cool idea. But I have to agree with Wynn. The after flight safety may be our weakest link.

Having the "Safety Plug" outside the aircraft, easily recognized and easily removed by non ECL people provides an added measure of safety. Also, during CLs transition period from wet systems to ECL I feel it is important for us to not only provide these safety devices for their obvious benefits but also for the political benefit of "outwardly" demonstrating to everyone that we have these safety devices on our ECL planes and that we have taken care of any potential safety problems from using E power.

There are many cool ways we could do it if we only flew with other ECL pilots. I would like to use the system I use on my sailplanes, a pin that has an attached "remove before flight" flag on it and is pulled OUT for power. ...... But for the next "X" number of years I think it is important that we make sure that our safety systems are as KIS as possible so that they can easily be operated by anyone before AND after our flight. For the time being it seems that a simple "Plug" that is physically REMOVED from the plane is a good device that we can all use as the STANDARD for ECL. This will make it much easier on all pilots at the flying field and at contests.

Maybe we can all come up with a standard universal "sign" for this next to the Safety Plug:  PULL for OFF ..... PULL - EMERGENCY - OFF  ..... IN EMERGENCY - PULL PLUG ..... REMOVE PLUG for OFF ...... Or ? (Please place your idea here :-)

Again, I like your idea, it is cool and very sano.  8)

Regards,  H^^
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Offline TDM

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Re: Nut-less switch mount
« Reply #11 on: September 21, 2010, 05:42:16 AM »
Maybe we can all come up with a standard universal "sign" for this next to the Safety Plug:  PULL for OFF ..... PULL - EMERGENCY - OFF  ..... IN EMERGENCY - PULL PLUG ..... REMOVE PLUG for OFF ...... Or ? (Please place your idea here :-)

Most machines have a Red Burton that is pushed in in case of emergency. It is pretty universal.

Wynn you are right I was thinking that the battery is empty at the end of flight. There is a fix to it we could have a longer extention on the button outside the plane so you can grab it from the outside to arm it (with a Flag PULL BEFORE FLIGHT) and push it in in case of emergency like the Red buttton on a machine tool.
Also I would have to switch the materials Aluminum instead of delrin and delrin instead of aluminum. We take an idea and we fintune it. The more feedback the better.

How about building in this plug the FM-9 timer you bolt it in and you do not need a switch for it anymore you just make a push button above or below it to push directly on the button on the circuit board?  :! :! :! :! :! Does anyone have a FM-9 Picture with a scale next to it so I can grab some dimmentions? Front and Side view.
« Last Edit: September 21, 2010, 06:06:45 AM by Traian Dorin Morosanu »
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Offline Wynn Robins

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Re: Nut-less switch mount
« Reply #12 on: September 21, 2010, 02:01:21 PM »
We need the switch in the battery to ESC line - not to the timer - so I dont think your idea would work,

To make your plug work - it would be great to have it "Pull" to be on - and "Push" to be off.  so when you are ready at the flight line to liven the system - you pull the plug out and it engages - at the end of the flight it can be pushed in - and disconnect.

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Offline TDM

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Re: Nut-less switch mount
« Reply #13 on: September 21, 2010, 03:08:06 PM »
I understand that what I was referring to was to add a second switch that would switch the timer on separate from the safety. So there are two switches one next to the other but built in the common block.

Yes it would be no problem doing what you said to pull for arming and push for disarming.
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Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Offline Warren Wagner

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Battery mounting
« Reply #14 on: September 22, 2010, 05:58:47 PM »
To answer Mikes request for information on the system for mounting my batteries...

This system for mounting batteries was copied from the system used by the "Smith Bros. Stunt Team" of
Tampa, FL.  I can't speak for what Jim and Wayne thought when building the battery hold down, but these
are the benefits as I see them.

1) The system is very simple to build.
2) There is air flow on all sides of the battery.
3) The holder makes minimum contact with the battery, therefore contributing to maximum cooling.
4) The oversized (in length) rails allow shifting of the battery fore and aft to adjust CG.
5) The rail and Velcro system is flexible, allowing different size batteries to be tried.

Note that when the rails were fabricated, recesses were provided under the rails to allow the Velcro to pass through.
(I'm looking for wider Velcro so that I can reduce the number of straps from 4 to 2.

Below is what it looks like.

Cheers.

Warren Wagner



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Offline Wynn Robins

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Re: Nut-less switch mount
« Reply #15 on: September 22, 2010, 06:26:12 PM »
heres my way on the T-rex. http://stunthanger.com/smf/index.php?topic=17249.0

Side mounted - no velco - just slide the battery in from the side

Cooling over 3 sides  - no need to flip your plane over to change your pack - just open the hatch - and away you go.

Ply tongue on the front  and magnet on the back hold the hatch in place - Simple and super easy to use.

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