5. Packing and terminals
In this part we are packing the regulators and all the wires into the enclosure, as well as assembling the boom stopper. Then we will pull the output wires through a slot and attach the terminals on to them. Some of this might require fiddling with the diameter of the wire to be inserted properly into the terminal. When moving the regulators, be sure to not force anything too much as to damage something. Making sure everything fits gently will be the best way to do so. The boom stopper has a cool name, and its purpose is to hold a fuse. In the event that something bad happened to draw > 10 A, then this fuse will blow first.
Pack the voltage regulators inside the enclosure as pictured. Then, apply tape to keep them in place.
Also apply tape to the battery connector. Ensure the battery connector is as close as possible to the shroud. It is okay if it is not in entirely, as we will be applying hot glue around it in a later step.
Bring all of the long output wires from the voltage regulators out from the enclosure.
Now, string the long output wires through the small slot at the back of the enclosure. They should all be able to fit through.
Here are all the wires going through the slot.
Here is another angle of all the wires going through the slot.
Now, organise the wires and tape them down to a surface. Obtain the spade connectors, and insert them onto the ends of the wires.
The spade connectors should fit easily onto the ends of the wires. If they do not, remove the connector, and try to cut some of the stranded wires in half horizontally. As in, essentially making the wire thinner. Be careful to not trim the wire too much, as to only have a few strands left. There should be a decent amount of strands still there. Try again and the wire should insert into the connector more easily.
Now, solder the wires to the spade connectors. One way of doing this is by inserting solder near where the wire will be exiting the connector hole, and use the soldering iron to melt it into place. Be careful to not overly add solder, as this can then melt the plastic casing. Additionally, try to not ‘blob’ the solder too much on the connection. Ideally it will be as flat as possible, to ensure the plate on the barrier block with the screw will have a flush surface to press against.
Select a wire and trace back to its origin voltage regulator. Apply some tape and label the connection. This will help down the road when it gets connected to the Bowie brain.
Here is what this looks like from a zoomed out perspective, if you wanted to see where the wires go.
There is one more task in this part. That is the boom stopper. Obtain the boom stopper from your kit, as well as the small 10A fuse.
Open the top of the fuse box. You will see two connection areas.
Insert the 10A fuse into the two connection areas. Orientation does not matter.
Ensure the 10A fuse is inserted all the way. There should be little to no extra space.
This is how it should be positioned. Terminals from each side of the fuse go in to each side of the connector – not two on one side.
Flip the lid on the boom stopper. It’s ready!
Insert the boom stopper into the battery connector. We will hopefully not need it for the next step, or in future steps, but it will be there as a precautionary measure.
Page last updated on: Fri Jan 17 21:51:24 2020