Archive for June 21st, 2010

HT GPS + Audio: Modified Plug Alignment Plates

As described there, I made a fixture and a small plate to hold 2.5 mm and 3.5 mm plugs in the proper alignment for the mic & speaker jacks on our ICOM IC-Z1A HTs. Knowing I was going to rebuild the interface boxes, I made several spare plates and tucked them into a small bag against future need.

Jack Plates - Oblique

Jack Plates - Oblique

Time passes.

Come to find out that the new gratuitously gold-plated 2.5 mm plugs in my stash have a slightly thicker front plate that doesn’t quite fit into the recess I milled in the plates for the old nickel-plated plugs. So I set up a little nest in on the Sherline’s table, snuggled each plate into the corner, and poked a 9/32-inch end mill 1 mm down into the plate. The net change was a 0.5 mm deeper recess. Sheesh.

Milling the plug plate recess

Milling the plug plate recess

I’d originally create the recess with helical milling, but I recently uncovered a stash of shiny-new end mills in a box: 9/32 is 7.31 mm, just about exactly what you want for a 7-mm dia plug front plate surrounded by a blob of fast-curing epoxy.

Plugs epoxied into plate

Plugs epoxied into plate

This epoxy just holds the plugs in the right position for wiring and initial testing. After the cable checks out, I’ll smoosh a blob of epoxy putty around the whole thing as before.

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