Step 5: Assembly

Picture of Assembly
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Short version:  Put it together.

Long version: The best components to start with are the DC jacks.  I used hot glue to hold them in place because the threaded portions weren't long enough to reach through the plastic and the aluminum and still have room for a nut.  Make sure that they are all aligned straight ( I messed this up) so that they will be easier to wire up.  Use lots of hot glue to make sure they won't get pushed in when being plugged into.

Next, install the transformer, fuse holder and IEC receptacle.  Use nuts and bolts for the IEC and the transformer, and use the nut supplied with the fuse holder to fasten it in place.  Also put the toggle switch in place so that you can wire up the AC portion of the circuit before the big caps and board get in the way.

That being said, now is a good time to wire up some more of the circuit.  Solder one wire from the primary (120V) side of the transformer to one of the locations on the back of the IEC receptacle.  The two that are next to each other are the Live and Neutral, the other lower one is the Earth which we won't use since this is a plastic housing.  Connect the other wire from the primary side of the transformer to the fuse holder, then solder a wire from the fuse holder to the toggle switch, and from the toggle switch back to the remaining connection on the IEC receptacle.  The chain should be:

IEC -> Transformer -> Fuse -> Toggle switch -> Back to IEC

Now that those are in place, put in the circuit board and caps.  To affix the capacitors, I put a zip tie around each one, and then rested them inside on the zip tie, and glued them in place.  

I'm curious, where did you connect all of the ground connections? I mean, if you were to use a metal project box, where would you connect the ground of the IEC connector? Directly to the chassis?
mattthegamer463 (author)  JakeJeckel3584 years ago
The ground is for safety, in the event that something happens in your power supply and the live AC wire touches the metal enclosure, it could kill someone who touches it. The ground cable, when connected to the metal housing, will protect the user by shorting the live AC to ground and throwing the breaker / blowing the fuse. With a plastic enclosure this danger is not present so it is not necessary.