DieselDummy's Battery Cover Buttons

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DieselDummy
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DieselDummy's Battery Cover Buttons

Post by DieselDummy » Fri Jan 26, 2018 9:57 pm

~Installation Guide for DieselDummy's 4 Button Battery Cover PCB~

For those who have ordered my kits, this is your install guide. I wouldn't consider this an expert level project but it is definitely not for first timers. Feel free to contact me with any questions, comments or concerns. :!: For your own sake while doing this install, BE PATIENT, and remember that removing more material is always easier than trying to replace it. :!:

~Part 1: PCB and Battery Cover~
MaterialsShow
Tools and materials you will need:
-drill
-1/16" (1.5mm) drill bit
-dremel
-dremel bit same size as drill bit
-small wood chisel (optional)
-small file (mine is 0.05x0.20" or 1.4x5.2mm)
-Xacto knife (scalpel)
-wire (anything 22awg-30awg)
-soldering supplies

In your kit, you will see:
-1 PCB (blue)
-2 Button sets
-2 Pogo assemblies
kit contentsShow
20180119_213759.jpg
kit contents
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InstructionsShow
Starting with your battery cover, looking at the outside, the button sets are going to sit horizontally in two of the recessed ridges of the cover. The L1&R1 button set will be in the second recess from the top and the L2&R2 button set will be in the very last recess.
battery cover outsideShow
20180119_214006.jpg
batt cover outside
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Looking at the inside of your battery cover, you will see two horizontal supports. You will need to remove the top support (the one with the screwdriver aimed at it).
battery cover supportsShow
20180119_214025.jpg
batt cover support
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My method was to grind down the support until it was close to being gone and then going over it with an 1/2" (13mm) wood chisel to make it look as if it was never there. It's a good idea to scuff the surface when done because you will be adding small amounts of epoxy adhesive which does not hold as well on glossy surfaces.
battery cover with support removedShow
20180119_215535.jpg
batt support removed
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When pressing your PCB inside the cover you want the bottom edge of the PCB to be resting on the bottom support of the battery cover (this is very important for the button alignment). DO NOT GLUE ANYTHING YET!
PCB test fitShow
20180119_215827.jpg
PCB test fit
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You may notice that the PCB fits a little tight within the cover. [This was done intentionally with a dual purpose. 1) not all battery covers are identical and as i said before, we can always take some material away much easier than we can add more. 2) a tighter tolerance will aid in securing the PCB and hopefully add durability during gameplay.] If your PCB fits too tight you will notice a slight concave in your battery cover...like this.
battery cover concaveShow
20180119_215948.jpg
cover concave
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Do not worry. With a few strokes of a file or light scrapes of a razor blade, you can shave the side edges of your PCB to fit tightly inside the cover without a concave effect.
battery cover flatShow
20180127_001933.jpg
cover flat
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The amount shaved off the PCB will be few thousandths of an inch (or hundredths of a mm). You will not damage your PCB by doing so and, as always, BE PATIENT. You can always remove more material, if it fits too loose the epoxy will hopefully compensate.

After you have your PCB and cover situated, you're ready to drill. The holes on the PCB are pilot holes for the buttons. The holes are at the absolute maximum width of the buttons. Make sure the bottom edge of the PCB is butted up to the bottom support of the battery cover and drill your holes.
pilot holesShow
20180119_221801.jpg
drill pilot holes
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Remove the PCB from the cover and inspect the outside of your cover. It should look like this.
drilled pilot holesShow
20180119_222008.jpg
cover drilled
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Very carefully with your dremel or drill, connect the holes horizontally within the recessed part of the battery cover outside. (I used the dremel to roughly connect the holes and my file to fine tune the slot.) :!: Be careful not to wander outside the recessed channel we are utilizing. The measurements allow for very little deviation. The button will fit perfectly if you stay in the lines! :!:

Once your slots are cut, do another test fit with the PCB and verify the switches and pilot holes line up.
slotted cover test fitShow
20180119_224032.jpg
cover slotted with PCB test fit
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Remove the PCB again and insert your buttons. Be sure they move freely within the cut slots. If necessary, use your file to carefully shape the opening so the buttons move freely in and out.
When installing the buttons, you'll notice the pieces on each side are offset from the centerline of each button. These pieces are there to keep the button from falling out. DO NOT CUT OR TRIM THEM! When setting the buttons in the holes, make sure these side pieces are closer to the top of the battery cover. (I have designed this to give the buttons a slight upturn when fully assembled. This makes a big difference in the ergonomic feel when pushing the buttons during gameplay.)
orientation of buttonsShow
20180120_010632.jpg
insert buttons
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Now that the buttons are set in the slots and moving freely, press your PCB back into the battery cover and give everything a test before gluing. The PCB should be sitting flush in the battery cover with everything fully assembled. All PCBs have been tested for continuity after soldering and before shipping. If there is an issue with a button not working, it is an alignment error.
Once everything is tested and you are confident in your install, you are ready for adhesive. I used a clear 5 minute epoxy. I know it holds better than hot glue and although it says "5 minute", i would let it sit overnight just to be safe.

When applying the epoxy or glue, focus on applying some on:
-the sides between the PCB and cover
-the bottom corners and overlap on to the PCB
adhesionShow
20180119_221801.jpg
drill pilot holes
20180119_221801.jpg (680.03 KiB) Viewed 3430 times
(I'm limited on post attachments so I'm recycling images)
:!: use caution around the bottom edge of the PCB. You don't want to glue the button into the slot! :!:
dont glue in the bottom button! see how close it is?Show
20180120_010632.jpg
insert buttons
20180120_010632.jpg (1.17 MiB) Viewed 3430 times
note: no adhesive is necessary at the top of the battery cover, the DMG case will hold it in up there.
My sincere apologies if anything in this install guide comes across as patronizing, it is nothing personal. I am a mechanic and i have to assume everyone is an idiot. Assuming certain levels of intelligence and common sense has bitten me in the ass too many times. :lol:

Pogo and DMG case install to follow.
Last edited by DieselDummy on Thu Feb 01, 2018 10:28 am, edited 2 times in total.

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~Installation Guide for DieselDummy's 4 Button Battery Cover PCB~

Post by DieselDummy » Sat Jan 27, 2018 12:07 am

~Part 2: Pogo Install~
InstructionsShow
Now that we have the battery cover set up, we are ready to get the pogo connectors installed. This part can be a bit tedious as far as the actual cutting/carving is concerned but I made the alignment portion easy. As always, I am open to comments or suggestions on how to make this process any easier and user friendly (that is the whole point of the beta test batch). Disclaimer: This project started off as something for myself. That being said, I had a specific idea in mind for what I wanted. If anyone has an idea of how to simplify the actual circuit connections to the DMG shell, feel free to voice them.

In my Interest Gauging thread I posted a photo of the pogo pins alignment to the PCB. Nothing has changed there. The two middle pins are the common ground and the two outside pins are for each button on that side of the DMG. The contact points on the PCB are actually solder pads. If you do not wish to use the pogos, you can solder you wires directly (I have not done that, so i can't help you with that style of install).
pogo to PCBShow
Untitled.jpg
pogo to PCB
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In the battery bay you will see a "ledge" directly above the stock openings on each side. That is where the pogo assembly will sit (outlined in white). For description purposes, i will refer to the "inside egde" of the battery bay (see yellow arrow). Do not get it confused withe the "outside edge" of the battery bay (see blue arrow). :!: Take a minute and look at the photo below and be sure that you understand this. Using the incorrect edge for alignment will result in circuits connecting incorrectly or not at all. :!:
get it? got it. Good!Show
20180120_224526.jpg
outlines
20180120_224526.jpg (303.87 KiB) Viewed 3272 times
In the next photo, you'll see the pogo to your right is already installed, ignore that one for now. Take your uninstalled pogo and just let it sit on the ledge like the one to the left of the photo.
pogo on ledgeShow
20180120_224354.jpg
set on ledge
20180120_224354.jpg (705.67 KiB) Viewed 3272 times
While the pogo is sitting on the ledge, make sure the side is butted up against the inside edge of the battery bay (remember the yellow arrow?), and mark it. I used a knife. You can use whatever you want, pen, sharpie, etc. All we are doing is tracing the perimeter of the pogo assembly to make cutting and alignment easier. (do not worry if the pogo looks asymmetrical, the measurement are correct and they are not specific to either side of the DMG)
mark itShow
20180120_224411.jpg
mark it
20180120_224411.jpg (282.37 KiB) Viewed 3272 times
Once that one line is marked, you can start cutting. Cut a thin slot from your mark to the inside edge of the battery bay. The hole should look like the next photo when you're done.... a slot just big enough for the bottom half of the pogo assembly to sit inside.
cutting step 1Show
20180120_225411.jpg
cutting step 1
20180120_225411.jpg (266.07 KiB) Viewed 3272 times
Take your file and fine tune the slot so the pogo fits in and sits on the ledge again like so...
pogo inside first cutShow
20180120_225443.jpg
pogo in fist cut
20180120_225443.jpg (302.77 KiB) Viewed 3272 times
With your pogo sitting in the slot, mark the top half perimeter of the pogo assembly and finish cutting the hole. On this step of cutting, you MUST remember what i said about being patient. You do not want to cut too deep. :!: Cutting the hole too deep will prevent the pogos from making proper contact with the PCB. :!: Take small bits at a time, TEST FIT OFTEN...and when it get close to being where you want it, USE YOUR FILE. The file will do a lot of work against this soft plastic. The file is your best friend here! :!:
finish marking perimeterShow
20180120_225619.jpg
finish marking perimeter
20180120_225619.jpg (270.93 KiB) Viewed 3272 times
The top edge of the pogo should sit flush against the top edge of the battery bay like in the outline
check the white outline againShow
20180120_224526.jpg
outlines
20180120_224526.jpg (303.87 KiB) Viewed 3272 times
:!: Be careful not to cut too deep :!:
The photo below is an example of a finished cut.
In that photo, the green arrow is pointing at the horizontal piece on the middle of the hole. This is your depth adjustment.
finish cut and depth adjustmentShow
20180129_230250.jpg
finished cut and depth adjustment
20180129_230250.jpg (194.24 KiB) Viewed 3272 times
A good strategy is to get the perimeter of the hole finished and, of course test fit to verify correct alignment with the PCB, then you can focus on getting the depth to where you want it. Too high, and it will flex the battery cover out in that corner (that drove me crazy). Too low and it will make little to no contact with the PCB. Good news is that with patience and the right file, getting the depth right is easy. The file I used fit perfectly in the hole that I accessed through the cartridge slot.
There are many more photos in the Interest Gauging thread (found in my signature) if you need more examples of installation. I think it would be a bit redundant to go over it all again. Also I wasn't sure if it's really necessary to go over the soldering of the pogos, therefor I didn't. If requested, I will but its late and I'm tired.
*If anyone with my kit has any questions or concerns about install, contact me.
Last edited by DieselDummy on Wed Nov 14, 2018 2:28 pm, edited 3 times in total.

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~Installation Guide for DieselDummy's 4 Button Battery Cover PCB~

Post by DieselDummy » Sat Jan 27, 2018 12:07 am

~3D Printing,Adjustments,maybe another poll?~

-HoolyHoo's printed battery cover-
Huge thanks to HoolyHoo for his 3D skills. He added 4 screw posts for added support and the option of a "no glue" install (his idea). And the design privides a much better fit for the PCB. Now you can save yourself time (and possibly some aggravation). Any new batches of PCBs will come with the holes for the screw posts. I'm also toying with the idea of offering an assembled product if there will be a pre-order in the future. At the very least, I can provide the dimensions for the screw holes on this thread in an update.
photos, courtesy of HoolyHoo
IMG_2468.jpeg
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20180131_190935.jpg
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Last edited by DieselDummy on Thu Feb 01, 2018 10:31 am, edited 3 times in total.

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Re: DieselDummy's Battery Cover Buttons

Post by HoolyHoo » Sat Jan 27, 2018 4:03 am

Very nice guide and idea ๐Ÿ˜€. As an idea, having a 3d printed battery back cover with your adjustments would be an easy alternative for some that may want to go that route. Some will prefer the original cover but having an easier option may appeal to others. Anyways, just a suggestion that should be pretty easy to design.

Thanks for your contribution, looking good ๐Ÿ˜€

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Re: DieselDummy's Battery Cover Buttons

Post by YaYa » Sat Jan 27, 2018 5:29 am

Very good so far ! :D
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Re: DieselDummy's Battery Cover Buttons

Post by DieselDummy » Sat Jan 27, 2018 8:15 am

HoolyHoo wrote: โ†‘
Sat Jan 27, 2018 4:03 am
Very nice guide and idea ๐Ÿ˜€. As an idea, having a 3d printed battery back cover with your adjustments would be an easy alternative for some that may want to go that route. Some will prefer the original cover but having an easier option may appeal to others. Anyways, just a suggestion that should be pretty easy to design.
Thank you. I was thinking the exact same thing. My only issue with that is I do not have the software or a printer. Regardless of how much I want one, i dont think i would get enough use out of it to make it worth the investment. I am open to someone else taking that task if they wish to. And I have some materials left (not a complete kit) if someone would like one for development I will send them no charge.

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Re: DieselDummy's Battery Cover Buttons

Post by HoolyHoo » Sat Jan 27, 2018 9:28 am

DieselDummy wrote: โ†‘
Sat Jan 27, 2018 8:15 am
HoolyHoo wrote: โ†‘
Sat Jan 27, 2018 4:03 am
Very nice guide and idea ๐Ÿ˜€. As an idea, having a 3d printed battery back cover with your adjustments would be an easy alternative for some that may want to go that route. Some will prefer the original cover but having an easier option may appeal to others. Anyways, just a suggestion that should be pretty easy to design.
Thank you. I was thinking the exact same thing. My only issue with that is I do not have the software or a printer. Regardless of how much I want one, i dont think i would get enough use out of it to make it worth the investment. I am open to someone else taking that task if they wish to. And I have some materials left (not a complete kit) if someone would like one for development I will send them no charge.
If you want I can whip that up for you. Do you have a dxf of your board design? With that I can probably make it really quick then I would just need an actual board to test fit. Let me know if you would like that.

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Re: DieselDummy's Battery Cover Buttons

Post by DieselDummy » Sat Jan 27, 2018 10:21 am

SpoilerShow
HoolyHoo wrote: โ†‘
Sat Jan 27, 2018 9:28 am
DieselDummy wrote: โ†‘
Sat Jan 27, 2018 8:15 am
HoolyHoo wrote: โ†‘
Sat Jan 27, 2018 4:03 am
Very nice guide and idea ๐Ÿ˜€. As an idea, having a 3d printed battery back cover with your adjustments would be an easy alternative for some that may want to go that route. Some will prefer the original cover but having an easier option may appeal to others. Anyways, just a suggestion that should be pretty easy to design.
Thank you. I was thinking the exact same thing. My only issue with that is I do not have the software or a printer. Regardless of how much I want one, i dont think i would get enough use out of it to make it worth the investment. I am open to someone else taking that task if they wish to. And I have some materials left (not a complete kit) if someone would like one for development I will send them no charge.
If you want I can whip that up for you. Do you have a dxf of your board design? With that I can probably make it really quick then I would just need an actual board to test fit. Let me know if you would like that.
That's an excellent idea. I don't have a dxf, that I know of, but I used the online design software from easyeda.com. let me check if I can download that file format. If not, a can invite you to join the "project" on the website and maybe that could help. I will do some research and send you a PM. Thanks, HoolyHoo.

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Re: DieselDummy's Battery Cover Buttons

Post by HoolyHoo » Sat Jan 27, 2018 10:42 am

DieselDummy wrote: โ†‘
Sat Jan 27, 2018 10:21 am
SpoilerShow
HoolyHoo wrote: โ†‘
Sat Jan 27, 2018 9:28 am
DieselDummy wrote: โ†‘
Sat Jan 27, 2018 8:15 am


Thank you. I was thinking the exact same thing. My only issue with that is I do not have the software or a printer. Regardless of how much I want one, i dont think i would get enough use out of it to make it worth the investment. I am open to someone else taking that task if they wish to. And I have some materials left (not a complete kit) if someone would like one for development I will send them no charge.
If you want I can whip that up for you. Do you have a dxf of your board design? With that I can probably make it really quick then I would just need an actual board to test fit. Let me know if you would like that.
That's an excellent idea. I don't have a dxf, that I know of, but I used the online design software from easyeda.com. let me check if I can download that file format. If not, a can invite you to join the "project" on the website and maybe that could help. I will do some research and send you a PM. Thanks, HoolyHoo.
Excellent, looking forward to help.

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Re: DieselDummy's Battery Cover Buttons

Post by DieselDummy » Tue Jan 30, 2018 12:16 am

PART 2 HAS BEEN UPDATED

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