31 March 2015

Sound Card Switchbox Version 2

After finding a nice, new box and the type of audio jacks that I was originally wanting, I decided to remake the sound card switchbox for Melty. The project took about 140 minutes (about 7 days and about 20 minutes per day) since I needed access to the heatshrink and heat gun at work (I'd rather not have to use the soldering iron or a lighter on the heatshrink) - I obviously worked on it a bit at a time during my lunch break, but I did drill out the holes and trim away part of the inside plastic at home; the 140 minutes does not include the amount of time that I spent planning it out.

I reused the cables (and switches) from version 1 along with using 27cm lengths of extra stereo cable to increase the length a bit, which turned out to be slightly excessive. The heatshrink I used around the cable splice didn't turn out too well, but I didn't want to waste time cutting all the heatshrink off to try the smaller-sized heatshrink. When I drilled the holes for the cables, the plastic chipped a bit, so I was forced to countersink the imperfections away, which ended up making it look kinda nice (it's very hard to see the hole past the countersink).

I used some scrap pieces of ribbon cable to connect the switches to the jacks, which makes it look much cleaner than the previous version. The ground/sleeve wires (whatever you want to call it) from the cables are not covered with heatshrink (except for the ribbon), since it wasn't entirely necessary and none of them are touching one another.

While I wanted to take a picture of the switch loose like I did with version 1, I didn't want to waste any time, so it wasn't possible at work, and disassembly wasn't an option because of the thread-locking compound on the switches (and jacks).

Sometimes it's surprising how nice something can look with some new parts.

Finalized schematic (which was originally done in pencil, but had to be inked due to smudging). "Scuffed" refers to the side I scuffed a bit while filing excess plastic away on the box and lid.


Insides and close-up view.


Front and rear 3/4 view (apologies for the massive glare on the rear 3/4 view).


Rear view (apologies for the lens flare). I decided against making/placing a "P" label since I'm one of those that can extrapolate from incomplete data.


View of the splices and a close-up view of the gap between the heatshrink and cable.


Front and rear 3/4 view after "installation" (The side with the "Lin/M$W" label will be visible to me when I move Melty into the closet of the other room).

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