Project list

USB Rotary Dial

Init

Time:

27.4.2014 9:23:58PM

Description:

I've had some old telephones laying around which gave me the idea to make this USB Rotary Dial.

It is based on 1-Key-Keyboard which uses software USB HID support and can be plugged into any USB host device (even USB OTG).

A rotary dial just can't be without antique wooden box so I had to make the prefect one. Only one side of the box is designed with LibreCAD. After that, all pieces of the box are drawn with Inkscape.

Sources and the box design can be found in the repository.

Schematics:

Schematic

Box CAD

Videos:

Pictures:

PCB front

PCB back

Antique view

Paper prototype

Stickers with the sawing plan

Preparing the wood panel

Sticked and ready for precision sawing

Everything fits!

Drilling the holes

The hole for the cutout

Sawing veeery carefully

Milling holes for the rotary dial holders

Test

Milling the cutout

It fits perfectly

Milling the holes for the rotary dial holder in the bottom cover

Filing the angled edges

Milling the angled edges

No more excess wood

Stickers removed

Gluing

Mixture of the glue and the sawdust

Filling the unperfections

Hidden unperfections

Preparing the bottom cover holders

Testing if the rotary dial can be removed once the cover holders are glued in place

Glued bottom cover holders

Sanding

The whole outer surface is now smooth

Forgotten hole for the wire

Countersinking holes for the screws

Painting the first layer

Varnishing after two layers of paint are dried

Dried and ready for assembly

Drilling holes in the bottom cover holders for the screws

Threading the holes

Preparing the wire

Making the connector with the terminals from the original telephone PCB

The connector is ready

Hotglued for insulation and mechanical strength

The bottom cover is mounted

Sawing the decorational screws

The decorational screws are glued into the front panel

Connector on the other side

Sticked foots around the bottom cover screws

Links:

• Mercurial Repository
• 1-Key-Keyboard

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