The initial batch of printed circuit boards I designed using KiCad EDA software arrived today from OSH Park.
I did do some cleanup of the board edges since they all had rough spots and one or more left over tabs. I removed the tabs and then used a disposable emery board to sand the edges smooth. Rounded the corners just a touch too.
All of the thru hole components fit in their mounting holes quite nicely. Which was a relief since I had ordered additional revised layout boards (which should arrive tomorrow) before I knew for certain that the footprints I had chosen were 100% correct.
The populated PCB was then temporarily attached to one truck's wires and to the LED lights attached to the roof of the PE passenger car. A small Lionel accessory transformer was used to supply power to the test track. Remarkably, the first test of the assembled PCB was successful. The LED's lit up.
After it was confirmed that the board was assembled correctly I attached the PCB to the car's floor using double sided tape. Then the permanent wiring was done including adding a PTC between the center rail rollers and inserting one of the PTC's conductors into one of the AC connectors terminals. The two wheel wiper wires were connected together and inserted into the other AC connector terminal. I soldered a short piece of solid wire to the ends of the LED connection wires and attached those wires to the appropriate + or - DC connector terminal. In my eagerness to get the roof put back on the car and see what it looked like assembled I didn't think to take a picture of the completed wiring.
Here is a picture of the car after the conversion was completed.
I think I will open this car up again after I decide what to use to block the light coming through the numerous holes that are in the bottom of these PE cars. Whether I fix the leaking light or not, the primary goal to eliminate the hot spots in the car's lighting has been accomplished. Now, I just have to dig out all the other PE passenger cars and complete the conversion on them before it gets warm enough to go fishing.
One more picture of the other side of the car. I was a little concerned since the LED lights are positioned off center because of molded in domes in the car's roof liner. On the next car I will experiment with removing the roof liner before mounting the LED light strip. I really don't see any difference in light intensity but my eyes aren't that great these days.
When power is turned off, the LED's take a few moments to completely fade out so I doubt that I will see any flickering of the LED lights in these cars. Whether I fix the leaking light or ignore it for now, the primary goal to eliminate the hot spots in the car's lighting has been accomplished. Now, I just have to dig out all the other PE passenger cars and complete the conversion on them before it gets warm enough to go fishing.
The pictures were all taken using my iPad, if I had used my camera they probably would have turned out better.
That's my story and I'm sticking to it. LOL.
