RJ-45 connector with terminal block



I've begun soldering.

Ribbon cable from X-keys to row/column breakout


MPCD solder board with first diodes




MPCD with all diodes

I will update my PDF tomorrow.

Thanks Joe.

I have been considering a similar project and I am actively watching this one to see how it goes.

I am looking at a different set of 'square' pushbuttons from Mouser - they are much smaller (at least I think they are). link

I would be cautious of buying pushbuttons much smaller than mine; the contact surface on mine is 11mm square, which is already smaller than fingertips.

The switches (and caps I might add) are about 12 mm square - they just are not as tall as the ones I see you selected. These switches are more in line with the size of the 4-way switch I see above (which I also added to my project parts list).

Work continues. This is the messy part.

I've been pondering how to house all of this stuff. I decided on hardboard (masonite), because it's cheap, stiff, relatively thin, and easy to drill, file, and sand because it's so soft. I cut all of the hardboard with my table saw.

Here is a panel with holes drilled for the pushbuttons:


With all of the switches in, I think it looks pretty nice for something homemade:


Once the switches are in, it's time to wire everything up:






4 panels 70mm tall will make up the sides of each enclosure:

2 RJ-45 connectors will be mounted in each enclosure in the side facing away from the user. Like any square or rectangular hole I need to make, the only way I have of getting the right shape is to drill a round hole and file until I get to where I want. Even with hardboard, this is a pretty lengthy and tiring process. I am very very glad the vast majority of my pushbuttons are round on the mounting end.

Lookin good Joe!

Don't forget "One second ago"

Been waiting to see additional progress on this one. Looks like you've got it nailed pretty well. I've been seriously looking at sheet metal for the housing as I have access to a bender(??? it folds the sheet to any angle from zero to 135 degrees.)

Nice job. If you think you'll be doing other construction projects, I have a word of advice: Get thee a Dremel tool! You'll never be sorry and those square holes will be ten-second walks in the park. Check it out.

10-second square holes, you say? I've still got at least 11 of them left...

How does one use a Dremel to cut square holes? You need a reciprocating action, not a rotary action, to get sharp corners.

The Dremel tool cuts straight lines through just about any material if you hve the correct bits. Last time I used mine, I cut the brass nuts off of my kitchen sink faucet and then cut larger holes in the stainless steel sink for the new faucet. Gotta get one Joe!

As for the dynamics, imagine a drill bit that - once you drill through the material - now slices sideways quite nicely. That's how one of the many bits works.

Id be extremely interested to see how you get the MFDs and displays to work. I mean, Id love to have the game output the data to the in-pit instruments. I dont know if Falcon 4 AF is setup to do that?

I'll keep watching your progress...and I'll stick to robot building

No, Falcon is not set up to do that. F4 SP4.2 can output everything but MFD video and HUD sympbology. F4 AF has less.

I'm only building this to have the switches available. I will have no working displays.


Vmann, I understand that you can punch a hole through something with the Dremel, and then side-load the cutting blade so that it cuts laterally. However, you still wind up with a round edge at the end of your cut. It certainly would be easier to finish off that last little bit with the file versus the whole thing, though...

$100 is pretty steep. I'll think about it.

I've gotten much more efficient at filing. No Dremel for me.

Construction is progressing nicely. Here you can see an almost-finished right MFD panel:


Here is the left MFD / main panel, also almost finished. You can see the left MFD solder board, the mian solder board to the X-keys matrix board, and the 6 RJ-45 connectors for other panels.


Inevitable with any project this complicated, I plugged these two in and found out I have some wiring errors. I'll be hunting them down in the next few days.

I'd show ya what Im working on but Im afraid you'd bow in my greatness at out geeking ya :p

So what's the status Joe?