D.I.Y. Illuminated tailcap

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pyro1son
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Still has 10mm spring pad. I will create 17 and 16mm versions later

Ignore silk screen for now was done quickly at work

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djozz
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pyro1son wrote:
!https://644db4de3505c40a0444-327723bce298e3ff5813fb42baeefbaa.ssl.cf1.ra...! !https://644db4de3505c40a0444-327723bce298e3ff5813fb42baeefbaa.ssl.cf1.ra...! Ignore silk screen for now was done quickly at work

Wow, you're fast! Cool

One thing, I believe in those little metal pots the electrical connection to the slider is also connected to the metal top of the pot, so if you swap the electrical connections of the pot, the metal top part of the pot is batt-minus and then it is no problem if the spring touches the pot.

djozz
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Btw, this is the solder pad information for one of the more available 3.5x3mm potentiometers (SR passives), is this the one you used already?:

pyro1son
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Think mine is smaller but I can create a new .lbr file later on

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djozz
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If the 17mm versioin is ready, I will order it right away, I think it will work and I think it is cool that it can be adjusted after assembly Smile

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I will finish it tonight and post here;

Once it’s been tested I may do a GB and build a batch of these for the non-solders

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Hah so I take it you do like the idea of pot on the spring side.

So what’s the verdict on pot footprint? Did we use a too-small size? I want to get my board updated tonight, I’ll need to order some little ones.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

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Be aware that those tiny pots tend to be touchy.

pyro1son
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I think the one I’m currently using is 2×2 but going to create and update to 3×3 as they are much more common.

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Halo… wrote:
Be aware that those tiny pots tend to be touchy.

Yeah…. Thats partly why I didn’t put mine in the springpad yet. I feel like I’m going to have to adjust it while power is applied to get it right anyways

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

djozz
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pilotdog68 wrote:
Hah so I take it you _do_ like the idea of pot on the spring side. So what's the verdict on pot footprint? Did we use a too-small size? I want to get my board updated tonight, I'll need to order some little ones.

LOL, I had missed that you suggested the pot-on-spring-side already, sorry about that Smile

The solder pad lay-out that I posted above is at least shared by two brands (SR Passives found on Ebay, Bourns found on Digikey) so that may be a desirable size?

Btw, in my EDC (that has a lighted tailcap) there is more than enough space and depth in the middle of the spring, even when fully compressed (a typical 3303 pot is just 1.5mm high)

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Have updated the .lbr file here

As mentioned above I have swapped the pins on the POT so the case is ground.

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djozz
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Jay, can I order that?

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pyro1son wrote:
I’m not 100% on which pads we need to be using for the pot. I think the way you have it set at the moment will be fixed at the maximum value of the POT

Based on this diagram, I don’t think it matters which of the two legs you use, you’ll just have to turn the pot the opposite way. I think that’s how it works.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

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Ahhh so it you use 1 and 3 its the max value. Thats ok then.

16mm

17mm

20mm

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djozz
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Perhaps to dot the i's and cross the t's, on the switch side the switch-pad that connects to the spring pad on the other side should not fully stretch to the edge to prevent a possible short to the tailcap-body.

mattlward
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Over time the slide will oxidize and require cleaning and movement to keep things working correctly. Think a volume knob that is introducing static when it is turned… Some of us here are old enough to remember that. So, keep a can of R5 handy!

EDC rotation:
FW1A, LH351D 4000k (second favorite)
FW3A, LH351D 3500k
FW3A, SST20 FD2 4000k
FW3A, Nichia 4000k sw40 r9080 (favorite light!)
FW3A, Cree XP-L Hi 5A3
Emisar D4V2, SST20 4000k

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Any tweaks or changes you guys want made just let me know I’ll finish it off tonight

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mattlward wrote:
...Over time...

In the course of this hobby, no EDC that I thought was the perfect one has lasted more than 3 months in my pocket before it was replaced by a different (different=always better Cool) one. But it is a good thing to think about that of course Smile

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can pyro/djozz link to the page where we are getting these pot measurements (or ordering from)?

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

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also, what springs are everyone using? I think I could get my switches to work if my springs were a tiny bit bigger.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

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pilotdog68 wrote:
can pyro/djozz link to the page where we are getting these pot measurements (or ordering from)?

I just ordered these:

http://www.ebay.com/itm/10x-Potentiometer-Trimmer-Resistor-SMD-SMT-Pot-3...

For the sizes, google 3303 potentiometer (most hits direct to Bourns pots), or 3x3 potentiometer.

For my EDC I used the stock switch that came with the Supfire S1, not the biggest one around but I think I can fit the 3x3.5x1.2mm pot in there.

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another link (I go for 100K but perhaps 50K is enough):

http://www.aliexpress.com/item/10PCS-3X3-100K-SMD-Adjustable-Resistor-Po...

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pilotdog68 wrote:
I think a slider switch in the middle of the spring is a better idea, but the switches I have are just barely too big. Has anyone found a switch smaller than 6.75*4.5mm?

Would you have the model # or a link to your switches?
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I was hoping for something closer to 25kohm…. I’ve never had to use a higher value than 22.1kohm, plus I have the other resistor pad in series bring it down a touch more. I’m worried 0-100kohm in one tiny pot is going to be a nightmare to tune..

Still better than soldering/unsoldering resistors till you get it right though.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

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Halo… wrote:
pilotdog68 wrote:
I think a slider switch in the middle of the spring is a better idea, but the switches I have are just barely too big. Has anyone found a switch smaller than 6.75*4.5mm?
Would you have the model # or a link to your switches?

I think this is what I have. Honestly I think it’ll fit under my springs, I’m just worried it’ll be too easy to bridge solder to the inside switch pins. I’m not worried about the outside pins because the case is neutral. I’ll do a board in about 4 hours.

http://www.ebay.com/itm/10-Slide-Power-Off-On-Panel-PCB-MINI-SMD-Switch-SPM-/120731615109?hash=item1c1c2a3f85:g:EbIAAOxykVNRw~l6

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

djozz
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pilotdog68 wrote:
I was hoping for something closer to 25kohm.... I've never had to use a higher value than 22.1kohm, plus I have the other resistor pad in series bring it down a touch more. I'm worried 0-100kohm in one tiny pot is going to be a nightmare to tune.. Still better than soldering/unsoldering resistors till you get it right though.

My idea is to bridge the other resistor pad and have the full range to adjust (the bleeder resistor will determine the maximum brightness) , and the 100K is to be able to effectively switch the lighted tail off. I will see about the tunability. (I have not found logarithmic pots in this size yet, just lineair ones. Come to think of it, if logarithmic pots are used, the orientation of the pot does matter Undecided)

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What is the orientation for logarithmic pots then? On mine with a linear pot, clockwise would make the led’s brighter.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

djozz
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pilotdog68 wrote:
What is the orientation for logarithmic pots then? On mine with a linear pot, clockwise would make the led's brighter.

don't know, have to look that up.....

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Mousers seems to only have the option for lineair potmeters in this size

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