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Picture of Heavy Duty Remote
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 My Parents own this old CRT TV from 1998. Over the years i often had to clean and repair the original TV remote, until the point it wear out completely. TV remotes often suffer from grease, human sweat or battery leakage which attack the sensitive pcb. So i bought a cheap universal remote, which then lasted for 3 years. Then i figured out, that my parents would only use the Volume-, Channel- and Power- buttons. The first idea was to built a durable remote out of a piece of wood, with wooden buttons and stuff, until i stumbled over an old 2-button-remote, which is used on construction sites, small cranes or elevators, on a flea market. Anyway, first i had to figure out, how to mount 3 additional buttons.

Tools required:
- Jigsaw
- cutter knife
- Screwdriver set
- hot glue gun
- different pliers
- sandpaper
- soldering Iron
- solder
- a dremel tool
- a drill
- multimeter

materials:
- (project box)?
- 4-5 tact switches from used pc-cases
- mounting sockets/ plastic brackets 
- different wires
- 2 identical pens
- 3 small screws  


Step 1: Disassembly

Picture of Disassembly
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While dissembling the industrial remote, i noticed, that  the actual switches were missing. Also the top socket was originally used for a small light bulb. Most of the bottom surface part of the "brick" remote had to be removed with a dremel tool.

Step 2: Power Button

I decided to use the light-bulb-socket for my custom made power button. For the knob i took a button from an old sweater, which could easily fit inside the socket, and painted it red varnish. The switch with the spring came from old pcb parts. Both parts, the switch and the knob had to be stabilized with a small tube in between and glued together. To fix it to the socket i used some mounting sockets from old PC casings. a small screw and lots of hot glue.

Step 3: Volume Buttons

Picture of Volume Buttons
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The original two buttons have an internal spring, which allows to press the knob with more comfort. Again
i took the plastic brackets with built in switches, screwed them underneath the sockets and glued everything tight.

Step 4: Channel Buttons

Picture of Channel Buttons
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Next i had to find some suitable knobs for the custom channel switches. I found these two identical pens with a perfect aluminum head. In order to extend the top part of the switch i used the parts from the pen and fitted the whole beast in the plastic bracket, which then could be glued. Then i drilled two holes on the top part of the "brick" and fixed the brackets with the switches underneath.

Step 5: Battery casing

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For the battery casing i reused the back part of the original remote. Had to cut it out with a jigsaw, clean up the edges with some sand paper and glue it inside the bottom part of the "brick".

Step 6: IR Orb

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Because of its anomalous look, i had to find some catchy looking Orb. Fortunately i had this old "eau de toilette" lying around. Its perfect. So i stuffed the led on some plastic cone inside the orb and glued everything in place.

Step 7: Soldering

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First i had to do the wiring job. For the PCB  i had to locate the traces for the 5 buttons. Best advice here is to hold the pcb against a light source and make some continuity tests with the multimeter. After i soldered all the wires and isolated everything with hot glue.

Step 8: The finished remote

Picture of the finished remote
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Finally i've cut out some labels for the volume buttons. Mission accomplished!
 
msmith1492 years ago
I swear know that did parents like it
Gabse2 years ago
You can not lose it :-)
clockdryve2 years ago
Moves a simple "throwing" of the remote from a LOOK OUT situation...to a trip to the emergency room :-)
mcsper2 years ago
I like this. the on and off could be one of those toggle kill switches from jets
franklande2 years ago
Good job! nice
espdp22 years ago
That is doggone sweet. Just don't throw it at the TV when you get fragged on Call Of Duty! Ha! ;-)
AJMansfield2 years ago
One last thing - I wouldn't have used the original remote's circuit, because sometimes the circuit itself can have problems. I would have put a microcontroller in there - probably an 8-pin picAXE or something - to do the IR transmitting. That way, you can broadcast at higher power, you have the added bonus of being able to change it to work with different types of TVs (even universal remotes don't work with every TV - you still have to dig out/look up the manual to figure out how to configure it to work with different ones), and you can program the remote to behave certain ways when needed. For instance, my TV has a problem that every time I turn it on, it turns closed captions on, so I would program it to turn them off every time I turn the TV on.
AJMansfield2 years ago
I would've just got a single 9 volt battery and used that, rather than cutting out the battery box from the old remote, which, on an old remote, is often half the reason the remote isn't good anymore (no battery cover, broken/bent contact springs, corrosion, etc).
AJMansfield2 years ago
That's a pretty good use for that part, I have a bunch of those sitting around from old computers with nothing to use them for.
LesB2 years ago
Really cool.
This opens up the possibility of using any old discarded box with switches to repurpose as a remote.
freelancing2 years ago
I heart this! My husband is a geek - has lots of remotes, but even with bifocals, it takes him 10 minutes to find the mute button! I would love to make one of these (with a few more buttons) for him... great idea. Thanks for sharing it!
Tomdf2 years ago
I dig the IR orb, it really gives it a vintage sci-fi feel.
Simply fantastic. In average, I buy a new remote every three months and for sure your heavy duty remote will be my next project. Great !!!
notimeoff2 years ago
This is outstanding! why didn't I think of this. I worked with that type of "button boxes" for 30 years. Great job !
r_harris22 years ago
And another bonus is that no one EVER has to ask the question "Are you sitting on the remote?"

I should make one of these for my Dad. He is a retired construction worker and has pretty bad eyesight these days, so it would be a hit on two counts :-)
cortexcmdr2 years ago
Do you have a part/model number of the 2-button-remote I might be able to look up? It's great! Nice work.
Google search for "commercial door control" or "crane pendant" will find you some similar products. Ebay has some Chinese made crane pendants for cheap. The door controllers seem to be pricier.
bigape (author)  fzumrk2 years ago
Its hard to find some cheap ones on ebay! Thx to fzumrk, i found one matching my german "brick" for 60 Bucks http://www.ebay.com/itm/221015135893. Still to expensive thou!

Better search for "pendant control" under business and industrial.
http://www.ebay.com/chp/business-industrial
stindall22 years ago
Awesome but I can't do this. I would buy one
Misac-kun2 years ago
Now you don't need to repair it anymore, it will live more than you.
wazzup1052 years ago
*lol* .. pretty awesome !
That is an amazing remote. But what about the channel changing buttons? No longer needed?
they are on step 4 :D
Ah, missed that the first time. The other buttons overwhelm them