3D print and a $3 buck converter!
While I was printing 18650 battery cases for my Baofeng and my Yaesu HTs, I was wondering what would happen if I built a regulated linear power for my Baofeng so I could run it from 12 volts. (You can buy a battery eliminator for about $14, but you’ll still have to cut the cigarette lighter adapter off to use with some other connector.) Back to the DIY…I did some rough math in my head and decided that a linear supply would be a waste of energy in heat that I didn’t want. PLA melts at a low temperature AND I was wanting to use the radio in a battery powered ARDF fox box so power consumption conservation is paramount! I decided I’d look at building a switching DC-DC buck converter which is about 100% more efficient compared to a linear supply (about 90% efficient overall).
After looking at the easy schematic, I quickly realized I could probably get one cheaper than the sum of the parts and shipping. Off to eBay I went. I was not disappointed. You can either buy them in bulk from China for about $5 or you can buy one from a guy in Georgia for $2.75. I’ve included the edited screen shot from eBay. Shipping is fast, and I am very pleased. I’ve bought two from the seller because I reversed the leads on the first one and burned it up. Hint: WATCH YOUR POLARITY! These are not forgiving.
The first step was to print the modified battery case. I used Tinfoil_Haberdashery’s original Baofeng 18650 case, but I used Tinkercad to cut out the middle so the buck converter could fit in it, and I added a hole in the back for the wires. (Here’s my STL file.)
All I had to do then was connect the wires! I chose to use a barrel connector on the back because of the power splitter I’m using in the fox box. I’m usually a fan of Anderson Powerpole connectors, but this time around I chose something different. The input and output polarities are clearly labeled on the circuit board. You need almost no electronics knowledge to make this work! Just watch your polarities.
Finally, you hook it up to a 12v supply and turn the little potentiometer until the voltage is where you want it. I chose 7.4 volts which is the nominal Li-ion battery voltage.
I printed someone else’s 18650 battery box for my Baofeng the other day, and it worked so well that I wanted the same thing for my Yaesu FT-60. I searched the web for a while, and I couldn’t find where anyone had actually printed a battery box for it. I found where they hacked up $25 AA battery boxes for the radio; I don’t want to hack that up. 🙂 For the cost of some Altoid tin steel and a little PLA plastic I was able to make a sweet battery box for my Yaesu FT-60R.
Check out Thingiverse for my post and the STL files.
Lately I have been reading about Amateur Radio fox hunting, and I wanted to make my very own fox. I saw some cool transmitters that are very small, and I have seen transmitters in ammo cans, and I really like the look of the ones in the ammo cans. I also set out to spend as little money as possible, so buying a small transmitter (around $100), was out of the question. I needed to use as much as I had at home.
The first thing to do was to acquire an ammo can from the Army Navy Surplus Store. This set me back $10 cash. I had some at home, but I didn’t want to empty them. Now, it’s time to get to the fun part.
Some people used Arduino microcontrollers to do the PTT and audio. I have an Arduino, but I really didn’t want to be limited to the audio created by software; I wanted to be able to use actual audio files right out of the box. This was what drove me to use a Raspberry Pi. Someone else used a Model B Pi as a transmitter. I didn’t want to go that route, but it looks really cool, and it was really small! I have more of the first rev B models than I do Arduinos anyways, and I’m always wondering what I could do with them since they pale in comparison to their newer model 3! The trade off is power consumption. The model B Raspi uses about 400mA. Using a newer model would improve this, but I’m using what I have in abundance.
The biggest part of this project is the Python program that I wrote. I am using an audio file from a text-to-morse audio converting website to create .wav files. Using the Raspi gives me the flexibility to play any type of audio file, and I can also access the GPIO port to control the radio or read switches. (For later revisions of the project…I’m thinking switches for different messages or a battery monitor to alert users the system is running low!)
Without going into step-by-step instructions on how I built it, the pictures should show a good representation of how this ammo can fox came to fruition. As of this writing I do not have the power supply in the box yet. Santa Claus is supposed to bring me that. I’m opting for a 12v/5v “security camera” power supply. The 5v will power the Pi, and the rest will run off the 12v side.
The Dummy Load
I built a 2.5 watt dummy load from ten 1/4 watt 510 ohm resistors soldered in parallel. The case to hold the dummy load was 3D printed and has vents to allow heat to escape. While it’s just a theory, I am hoping that having the radio transmit into the dummy load might make it harder to find. I won’t be able to test this out in the field until I have the portable power supply. Carrying around the deep cycle marine battery isn’t any fun, and certainly expands the level of suspicion of a box with an antenna on it.
I had to look at a diagram for how the PTT and mic for the FT-60 worked. The system I devised might work for other radios if the jack is adapted for the other radios. I have a Baofeng that I would like to use, but the 3.5mm jack is wired differently AND I do not have a way to power it externally, yet. A battery eliminator is about $3 on eBay. A work around would be to use your radio’s VOX setting. In this case, you could EASILY omit this circuit altogether and just run an audio cable to a Baofeng (cheap).
I wired the circuit for my FT-60 on a “surface mount style” board. I used a Dremel tool to etch a few pads. I’m really liking how fast I can throw together a working prototype using this method. I used a 2-pin header to connect the interface to the Raspberry Pi GPIO using jumper wires. (Hint: The schematic/wiring diagram is near the beginning of this long article.)
The 3D Printed Objects
The next thing I wanted to do was 3D print the other parts that I needed to mount the radio controlling circuit, the Raspberry Pi, and the radio into the ammo can. I haven’t had my 3D printer long, but I figured out how to use Tinkercad to create custom parts and learned how to download pre-designed stuff from Thingiverse. Piece of cake!
I printed four parts for the fox box: the dummy load housing, the Raspberry Pi case, the radio clip mount, and the interface box. It’s amazing what you can accomplish with a 3D printer. Having custom parts has never been so easy. All you have to do is design it or find it and print it. Boom!
The Power Supply
The supply I chose for this project isn’t a gel cell like most use. I had a choice to make; I could use the 12v gel cell and make a 5v linear regulator or I could just buy a supply that had both power supplies already built. This one is by TalentCell on Amazon and sells for about $34. It is marketed towards LED strip lighting and CCTV cameras. It should fit perfectly in the fox box based on the dimensions. At 12V 6Ah, it should be able to power the fox long enough for simple hunts. Later on it might be cool to add a power connector to the outside of the fox so it can be charged without opening the ammo can. I probably have the parts for this is the garage. I’m leaving room for improvement.
The Working Prototype
I want to share the working prototype as a conclusion. This was my test program to see how things would work before actually putting the parts in an ammo can. I was using a big screen TV as my monitor so I could type the program. Proof of concept! Are you planning on making a fox box? Share your stuff in the comments below.
The kids get a chance to talk with Santa on the 3.916 Santa Net, and you can get a snapshot of what my station looks like. The station changes all the time! Merry Christmas from W1RCP and the kiddos.
I’ve been watching videos of guys on ham radio operating (especially some of the guys on the 3.916 nets), and I’ve been wondering how to hook a “regular” microphone through a mixer to my radio. I watched a video by Bob Heil that did a good job of explaining how to do it (LINK). Then I watched a video of why you would want to do it (LINK). I had all of the parts to build a solution in my junk bin!
The first thing I learned was something I basically already knew; I needed to isolate the mixer from the radio using an isolation transformer. I prefer this method so that there are not any ground loops. Back when Radio Shack was alive I purchased two of them to use as a digital interface for my 10m rig. I since upgraded to a SignLink to do that work so the DIY interface went into my parts bin.
I started my research by looking at some available interface schematics on the web. There were several designs that used chokes, but I decided that I didn’t want to do that. I drew up a schematic in my engineering notebook with a circuit board and box idea. The circuit is quite simple. The 600:600 transformer connects one side to the input jack that comes from the mixer. The other side of the transformer connects to a potentiometer and two resistors. Then the output is fed through another audio jack to the radio. Another momentary switch is used as the PTT. Look at the picture of this switch! It’s from another man’s junk bin. Free and awesome looking.
I designed a box to house it in using Tinkercad.com and used my 3D printer to create the box and switch case. Wiring it up was easy. I tested it out on a net the other night before it was put in the box, and audio reports came back good. It works. I don’t have another receiver to listen to it, so I cannot give any info as to how my actual sound “sounds”, but I know that the interface works!
Getting the audio and the PTT to the radio was a different story. Like the SignaLink and other interfaces, there is usually a modular plug that breaks out into a radio’s specific plug so I tried to make my interface similar. I broke the rules just a little
with the PTT switch since I wired it straight to the radio. There’s no picture of the plug to the radio. If you’ve seen one you’ve almost seen them all. What sets my kit apart is this switch. Good night! I love how it looks. I’m pretty sure that is an aircraft switch. I threw most of the crap that I inherited from a guy, but these switches looked too cool to toss. I have more, and I’ll probably do this again for something else!
I’ll leave you with an image of the inside of the box, and an image of the schematic. This was a fun build, and I look forward to using it on the air. The Santa net on 3.916MHz starts tomorrow, so I know the kids and I will be using it. Some upgrades in the future will be a mixer that actually has the right EQ as mentioned in the videos. My main goal was the get where I could actually use my Shure SM-58 and the mixer. Now I can look to upgrade. Perhaps I’ll own a Heil in the future!!!
Earlier this year (2016) I was on the radio on SSB, and I received an audio report during a longer conversation that described my audio as nasally and difficult to listen to. I did some research on the Astatic D-104, and there was a modification that was supposed to change the characteristics of the mic. I attempted this mod by following a step-by-step PDF which involved using a JFET, but for some strange reason it didn’t work well with my radio. It didn’t have enough audio output to push the finals of my radio! Time to put it back to how it was… The problem is that I don’t remember, and I didn’t document it before tearing it apart the first time. Continue reading Astatic D-104 Lollipop Mic Restoration
Prepare for Disaster
It happened once before when I was KK4FGM. I had a logbook on a computer that died, and I lost my entire logbook. It was never uploaded to LOTW, QRZ, eQSL, or anywhere, so I lost all credit for any awards or recollection! Since getting back into HF in December 2015, I have made 100% sure that I have duplicate copies of my logs and other important data on a separate device. Continue reading Raspberry PI File Server: Backup Ham Radio Data