Need a Switch Enclosure
in [Motorcycles]
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From: Robert Bolton on 9 Jun 2010 04:02 The last step in connecting the radio to the intercom is to mount a two pole, double throw toggle switch. The plan is that with the double throw switch, I'll be able to have two easily controlled inputs into the intercom. One position will connect the radio to the intercom while the other position will connect a female stereo receptacle to the intercom. In this way, I can easily insert any device into the intercom, and switch to it as I choose. I'll be mounting the switch onto the handlebars for lack of any other place where I could reach it while riding. The toggle switch is rated 125 volts, and is way overbuilt for the low power signal I will be switching, but it was all I could find that offered a means of making it watertight. With the toggle, a rubber boot can be threaded onto the switch to prevent water from entering via the toggle handle. I intend to mount the switch on the left bar, crudely where the bar bends and goes vertical. My problem is finding a suitable box, and discovering a suitable means for mounting it. The Box - I haven't been able to find a suitable switch enclosure, so to date my two options are using an oblong tube that once held vials of Crystal Lite lemonade sweetened with Aspartame, and a bottle that contains mildew killer. The Crystal Light container looks like this - http://www.kraftrecipes.com/Products/ProductInfoDisplay.aspx?SiteId=1&Product=4300095023 It may not be obvious, but the container is oblong, and contains a cap that is as large as the container. The label is shrink wrap and is easily removed, leaving a clear, plastic, oblong container. The plan for this would be to cut the container so it's not so long, drill a hole in it's bottom large enough to mount the toggle, and drill a smaller hole in the cap large enough to permit the conductors to exit. Because the cap is the same size as the container, The cap will fit back on the container even after I cut the container in half to reduce its length. The container would then be tie wrapped upside down onto the handlebar, the toggle switch slid up inside the container up through the new hole, while the conductors would exit the container via the cap. The problem with this is that the Crystal Light container is much larger in all dimensions, and so would look unsightly. The toggle is perhaps 1/2 inch wide by 1 inch long, while the dimensions of the oblong are maybe 1-7/8 inches by 2-3/4 inches. Option 2 is to use this container - http://www.natlallergy.com/prod/1288/m1-advanced-mildewcide-paint-additive-mold-inhibitor.html It's a relatively small, rectangular bottle that is sized just right to house the toggle switch without being overly large, and is short enough in length that it doesn't need to be altered at all. The problem with this container is that the bottle opening is not large enough to permit the toggle to be inserted into it. So, what I'm thinking about doing is to cut the bottle across its midsection, insert the switch, stitch the severed pieces back together, and seal. If you can visualize it, this bottle would also be tie-wrapped upside down to the handle bar, with the toggle mounted in it's bottom (which is facing up). What I'd really like is an enclosure that is perfect in every way, like a cigarette pack box. I haven't seen one in years, but a box into which you slip your pack of cigarettes. Anyone have a better idea of where to get a box that's around 1-1/8x2x3? The switch would mount in the 1-1/8x2 face. Anything prettier than a tie wrap to attach the box? I'm 90% certain I'll be using the mildew bottle, but I'm still trying to look around. The problem there is that I'm tethered to the wife/wheelchair, and it gets tiresome hauling both of them in and out of the minivan. Robert Thx,
From: Mark Olson on 9 Jun 2010 06:28 Robert Bolton wrote: [snip story of searching for a box to mount a toggle switch in] > What I'd really like is an enclosure that is perfect in every way, > like a cigarette pack box. I haven't seen one in years, but a box > into which you slip your pack of cigarettes. > > Anyone have a better idea of where to get a box that's around > 1-1/8x2x3? The switch would mount in the 1-1/8x2 face. > > Anything prettier than a tie wrap to attach the box? Digi-Key. They have TONS of little boxes, and shipping is reasonable and quick. Their website is pretty decent for doing parametric searches, too. They can also sell you a switch and a jack and every other part of this project. You can go to a motorcycle-oriented store online and buy a handlebar mounted switch purpose made for mounting on a motorcycle that is waterproof, but what's the fun in that?
From: S'mee on 9 Jun 2010 08:49 On Jun 9, 2:02 am, Robert Bolton <robertboltond...(a)gci.net> wrote: http://www.aerostich.com/prevent-or-repair?cat=199&p=2 Should have something that appeals...none with chrome though.* *that's a plus
From: Rob Kleinschmidt on 9 Jun 2010 10:48 On Jun 9, 12:02 am, Robert Bolton <robertboltond...(a)gci.net> wrote: > The last step in connecting the radio to the intercom is to mount a > two pole, double throw toggle switch. > Anyone have a better idea of where to get a box that's around > 1-1/8x2x3? The switch would mount in the 1-1/8x2 face. > > Anything prettier than a tie wrap to attach the box? > > I'm 90% certain I'll be using the mildew bottle, but I'm still trying > to look around. The problem there is that I'm tethered to the > wife/wheelchair, and it gets tiresome hauling both of them in and out > of the minivan. I recently mounted a toggle switch for my heated grips. I formed a bracket using a short section of L shaped aluminum angle. I was able to round the bottom of the L to better conform to the handlebars. I drilled a hole for the toggle and then beveled off the sharp corners. I don't recall I secured it with a hose clamp or tie wrap. To protect the switch, I used a section of narrow bicycle inner tube which slips tightly over the switch. The end covering the cable has stapled folds to narrow it down to the width of the cable.
From: Robert Bolton on 10 Jun 2010 23:28
On Wed, 09 Jun 2010 05:28:18 -0500, Mark Olson <olsonm(a)tiny.invalid> wrote: >Robert Bolton wrote: > >[snip story of searching for a box to mount a toggle switch in] > >> What I'd really like is an enclosure that is perfect in every way, >> like a cigarette pack box. I haven't seen one in years, but a box >> into which you slip your pack of cigarettes. >> >> Anyone have a better idea of where to get a box that's around >> 1-1/8x2x3? The switch would mount in the 1-1/8x2 face. >> >> Anything prettier than a tie wrap to attach the box? > >Digi-Key. They have TONS of little boxes, and shipping is >reasonable and quick. Their website is pretty decent for >doing parametric searches, too. They can also sell you a >switch and a jack and every other part of this project. > Thanks, it's a good site. I'd browsed through either Digi or Mouser awhile back, but for some reason didn't find anything. Perhaps I was searching during the time when the wife was still in her injury infancy. I wasn't getting much sleep then. This time around I did find one or two of the size I need that would probably work. >You can go to a motorcycle-oriented store online and buy >a handlebar mounted switch purpose made for mounting on a >motorcycle that is waterproof, but what's the fun in that? > None of the ones I saw were two pole double throw, or a variant of 2P2D that would permit me to select two between two stereo inputs. Being a little clearer minded now though, Kith's link has me thinking of getting one and replacing the switch, dimensions permitting. Robert |