Introduction: Build a Resistor/Capacitor Selection Box
- 10-turn potentiometers for precise resistances
- Low-resistance protection button
- Wire terminals
- Twenty-two capacitors on rotary two rotary switches
- Series or Parallel cap orientation switch
Step 1: Tools & Materials
- 4x Binding posts
- 2x 1 Pole 12 Throw rotary switches
- 1 Pole 6 Throw rotary switch
- 10k Pot (multi-turn is best for increased accuracy)
- 100k Pot (multi-turn optional)
- DPDT slide switch
- 2x 100k 1% resistors
- 3x 200k 1% resistors
- 1M 1% resistor
- 4.5" x 6" x 3" project box
- 5x Knobs
- Ribbon cable
- Drill and various bits
- Hot glue gun
- Soldering Iron
- Phillips Screwdriver
- Tin snips
- Square needle file
- Center punch
Step 2: Schematic and Template
Here is the schematic and the template that I created for this project. The template is intended for a 4.5" by 6" box.
To see a larger version of both, mouse over them and click the i symbol that appears in the top left corner. This will take you to the page where you can view the original image size.
The schematic is two separate pieces, the resistance portion and the capacitance portion. The capacitance portion is essentially two "variable caps" consisting of a rotary switch and 11 caps each. A DPDT toggle allows them to move from a parallel to series configuration when needed, to get more combinational values.
The resistance portion is a 1k ohm resistor on a button (to act as a low-ohm safety, when not pressed total resistance cannot go below 1000 ohms), two potentiometers, and a rotary switch for additional resistance options.
Step 3: Template Design and Drilling
I have supplied my template for anyone to use, or you can make your own. The dimensions are 4.5" by 6".
To transfer the template to the box, print it out to-scale and cut around the border. Tape the template in place on the top of the enclosure, and use the center punch and punch marks through all the black holes on the template.
Remove the template and drill a hole in each spot using a 1/8" bit. This will be a pilot hole before the larger drill bits. Measure the diameter of the switches and potentiometers, and drill appropriately sized holes in the appropriate locations.
For the switch, drill two holes using a bit the width of the black square on the template, then use a square-shaped file to remove the remaining material. (See images below)
Step 4: Assembly and Wiring
To make a cheap, simple, durable template, print a fresh copy and have it laminated by a local copy shop, or if you happen to have one at home. Cut the edges to the right shape and hold the enclosure up in the air with the template on the front of the enclosure, and look into the back of the enclosure with a light in front. Use the light to line up the holes to the center of the holes that you drilled for the parts, and tape it in place.
Next take a craft knife and cut into each hole, and remove all the laminated paper which covers the hole in the plastic. Insert each component through their respective hole and tighten the nuts. The switch is held in place with hot glue.
I used six-conductor rainbow ribbon cable to solder the rotary switches to the circuit board I used for the capacitors. This gives it more flexibility and keeps the wiring easier to handle.
Since the caps for each switch are all tied together by their negative leads, I soldered them in place with all their negative leads in a column, soldered together. The resistors are in a similar arrangement. The way I laid it out is probably not the most effective way to put them. If they were all in a long row instead of in multiple columns, this would make for a long thin board with all the wires along one side, and would be less cluttered to wire.
The low-resistance protection resistor can just go across the two pins of the button, as shown.
Step 5: Complete!
I hope you enjoyed reading this guide to building your own resistor/capacitor selection box. I would love to hear any suggestions on what I could add/change to make this box more versatile and functional.
Thanks for reading, and please post any comments, questions and suggestions you may have.