CRX Rotary - 6th Annual BLF/ Old Lumens Contest Winner

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Magnetic pill contact board & wiring.

I decided to use some copper dual sided 1.5mm thick FR4 board here for the pill contact plate.

Marked out, cut the board with snips, filed and smoothed the edges with sharpening stones until made good into a circle.

This disc fits nicely into the brass ring of the pill but protrudes enough to keep the top copper layer clear of contact.

Marked centre circle in pill contact board, drilled a 1.5mm hole and removed some copper from the reverse side to avoid electrical shorts.

20 AWG silicone positive wire end stripped and put through board hole, this will be soldered to the side of the positive contact magnet.
Showing how the pill goes together.

Three 2mm diameter holes drilled in the pill for wires, the negative wire will come out through the side of the pill and be soldered there.
Soldering of a 6mm x 2mm neodymium magnet onto board next to wire for positive contact point.
I used more magnets stacked on the board to keep the ones on front in place and take away some heat as too much heat will demagnetize the delicate rare earth magnets, you got to be quick soldering these!

Wires poked through pill holes, contact board JB welded in place, 20 AWG negative soldered to pill and unit cleaned up.

JB weld applied around positive contact magnet and test :THUMBS-UP:

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