javeryh's Small-ish Bartop ["Jack Attack!"]

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javeryh:
Some more baby steps. I think I figured out the button mod.

All I did was shave down the tab on the button insert. I had thought about trying to cram a smaller button inside but I couldn't work out how to get it to stay in place. I must have opened 10 different bags of washers at Home Depot trying to find something that would keep everything in place. No dice.

As you can see the rectangular hole was still there once I removed the tab.

This was really beneficial because it still allowed the tab on the microswitch to fit securely. I did have to shave down the corners on the switch so it would fit inside of the button insert.

I need to figure out a way to permanently secure the microswitch in place. I'm thinking of just using some super glue - will that be a tight enough bond between plastic? It needs to hold up over thousands of button presses.

Here is the result:

I will most likely solder the wires onto the switch just to be safe. It's not like I'll ever have to remove it.

You can't even tell from the outside!

Tomorrow I'll glue the switch in place... probably. I do want to sleep on it first. Next up - installing the monitor! :cheers:

Laythe:
Good save!

Were it me, I'd probably go for a 2-part 15 minute epoxy for mounting the microswitch, rough up the sides a little with a razor knife or file to give it some texture to grip.

(Superglue might work, but I hate getting that white fog in places I didn't expect, so I'm always leery of using it around clear plastic. Might work fine, though.)

javeryh:

--- Quote from: Laythe on June 07, 2019, 03:26:14 am ---Good save!

Were it me, I'd probably go for a 2-part 15 minute epoxy for mounting the microswitch, rough up the sides a little with a razor knife or file to give it some texture to grip.

(Superglue might work, but I hate getting that white fog in places I didn't expect, so I'm always leery of using it around clear plastic. Might work fine, though.)

--- End quote ---

Thanks - that's a good idea. I also hate the mess superglue leaves so an epoxy might be the way to go. The issue is going to be holding it exactly in place while the epoxy dries. There is nothing preventing the button cap with the switch from "falling" through the square hole in the button casing. In order to get it to work properly I'll have to eyeball it so the amount the button sticks out beyond the bezel matches the others and somehow apply the epoxy. I'm a little stumped - I wish there was a way to get it to be exactly where I want and then add the epoxy.

PL1:

--- Quote from: javeryh on June 07, 2019, 01:45:04 pm ---I wish there was a way to get it to be exactly where I want and then add the epoxy.

--- End quote ---
You don't need epoxy, you have a spare button and cardboard.

1. Carefully cut the sides away from the bottom of the spare button body leaving a round mounting washer with the perfectly-sized rectangular hole for the microswitch.

2. Make spacer washers from cardboard.

3. Put the mounting washer with microswitch on top of cardboard spacers in the button body and cover it all with the button cap.

Scott

javeryh:
Well if there’s 2 ways to do something I’m 100% guaranteed to get it wrong the first time.

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