AP5, Pegasus/AP3-4/EUPURS Metal Case Design

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daveejhitchins
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AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Fri Dec 01, 2017 6:30 pm

Finally had more time to complete these three drawings. The EUPURS case was the most difficult, as there were no mounting holes!

I've still to double check everything, however, I believe we're good to go . . . Edit: all checked now and out for quotation.

Attached ane snapshots and PDFs. Note: I've still to complete the dimensioning. Most of it's complete but I've not shown it in these drawings. I'll attach more later with dimensions plus the actual AutoCAD files. Edit: Attached files all updated.
Pegasus - AP3-4 Case.pdf
(94.81 KiB) Downloaded 67 times
EUPERS Case.pdf
(93.75 KiB) Downloaded 53 times
AP5 Case.pdf
(93.61 KiB) Downloaded 55 times
Dave H :D
Metal Case Designs.zip
(653.19 KiB) Downloaded 29 times
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Wed Dec 27, 2017 9:00 am

Above information now updated. Drawings in for quotation with the case manufacturers and painters.

Dave H :D
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Wed Jan 10, 2018 1:32 pm

All three cases are now ordered. I'll receive prototypes first - so I'll pop some photos up here when they arrive.

Dave H :D
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by danielj » Wed Jan 10, 2018 1:47 pm

\:D/

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Thu Feb 22, 2018 10:18 am

Just a quick update . . . Taking a lot longer than anticipated - sorry . . . Cases into the paint shop early next week.

Dave H :D
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by marcusjambler » Thu Feb 22, 2018 10:29 am

=D> =D> nice one Dave

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Thu Feb 22, 2018 3:58 pm

While I'm here and remembering :oops: One of the reasons the whole project has taken so long is MartinB's EUPURS. No fixing holes! So, I finally have a solution - it involves drilling holes in the EUPURS! But it's relatively easy e.g. no measurements! . . . There is 'one' hole that isn't used and becomes our point-of-reference: the centre hole of the battery holder (sorry if you are actually using this, however, IIRC, the battery circuit doesn't work). Firstly you cut the track coming from the hole (there'll be a photo showing this). Then you drill a 3.2mm hole, using the battery centre contact hole as its guide. You then fit the board into the case and secure using the hardware provided (more photos here) Once you're happy you have the board central in the case (the fixing should be tight enough to stop the board from moving) you then use the other two board mounting holes, in the case, as a template for two more 3.2mm holes. Job done . . . One hole is close to tracks so I'll be providing a metal screw with plastic spacer and washer for this position. Two holes are close to IC sockets and require the Nut holding steady while the screw is tightened - but all doable.

Dave H :D
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by crj » Thu Feb 22, 2018 5:47 pm

Just out of interest, what's the ballpark price for this kind of thing, for what kind of quantity?

For plastic, injection moulding has a setup fee in the mid-thousands, vacuum forming approaches a thousand, and the cost per unit for 3D printing doesn't decline with volume. I'm wondering how metal compares.

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Thu Feb 22, 2018 6:24 pm

Just out of interest, what's the ballpark price for this kind of thing, for what kind of quantity?
I'm having made a total of 200 pieces - Individually charged as three products for the cutting and forming and made some quantity saving at the painters.

Prices are tentative (shouldn't move - just haven't got the proforma from the painters, yet) at:

AP5 £7.16
Pegasus £6.22 - The new AP3/4 will also use this case
EUPURS £7.54

A little more than I had hoped, however, good strong cases that should last a lifetime - and colour matched to the current AP3/4 case.

Dave H :D
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by 1024MAK » Thu Feb 22, 2018 6:35 pm

daveejhitchins wrote:...EUPURS... There is 'one' hole that isn't used and becomes our point-of-reference: the centre hole of the battery holder (sorry if you are actually using this, however, IIRC, the battery circuit doesn't work).
Not entirely true. The battery backup circuit does have issues (including the battery holder pads on the PCB being the wrong way round / incorrect polarity, and logic modifications needed to prevent data being overwritten in a SRAM), but once these have been fixed, it does work.

How many people use it, is another matter...

Mark
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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by 1024MAK » Thu Feb 22, 2018 6:41 pm

daveejhitchins wrote:Just a quick update . . . Taking a lot longer than anticipated - sorry . . . Cases into the paint shop early next week.

Dave H :D
Sounds like good progress :D

I look forward to receiving some from you :wink:

Mark
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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by crj » Fri Feb 23, 2018 12:32 am

daveejhitchins wrote:Prices are tentative (shouldn't move - just haven't got the proforma from the painters, yet) at:

AP5 £7.16
Pegasus £6.22 - The new AP3/4 will also use this case
EUPURS £7.54
Hmm. that's slightly cheaper than one-off 3D printing, but not massively so.

Good to know, though - thanks.

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by paulb » Fri Feb 23, 2018 3:25 pm

crj wrote:
daveejhitchins wrote:Prices are tentative (shouldn't move - just haven't got the proforma from the painters, yet) at:

AP5 £7.16
Pegasus £6.22 - The new AP3/4 will also use this case
EUPURS £7.54
Hmm. that's slightly cheaper than one-off 3D printing, but not massively so.
Dave H would know what the "home printing" costs are, but compared to places like Shapeways it is very cheap.

Taking the sheet metal approach would have been my choice if I had to do any of this in volume, partly for cost reasons, partly not to have to mess around figuring out a printing approach that needs to provide robust output and not take up every hour of the day trying to meet the demand.

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Sat Mar 03, 2018 4:59 pm

Sorry, some weather related delays and me being away for a week <sigh>

I've build most of the AP5s that needed building, so I've not been idle . . . Kits next . . .

Dave H :D
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Mon Mar 12, 2018 3:31 pm

IMG_2212.jpg
Painters tomorrow . . .

Dave H :D
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Tue Mar 20, 2018 10:27 am

Sorry guys . . . The cases are at the painters, however, I see another delay on the horizon: Me taking a week off to have yet another bout of cellulitis sorted at the local hospital - Not certain yet but it looks that way - - Bugger :(

Dave H :D
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by rharper » Tue Mar 20, 2018 12:21 pm

Commiserations :(
My brother-in-law had cellulitis. It took quite a while to get on top of it including some recurrence.
Patience is required by all.
Best wishes,
Ray
Raycomp

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Thu Apr 12, 2018 3:30 pm

Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Thu Apr 12, 2018 4:32 pm

EUPERS Case:

Note: This was the most difficult one and the case can only be used if you are NOT using the battery!

It involves:
1) A track cut - to isolate the centre battery connection.
2) Enlarging the centre battery connector hole.
3) Marking and drilling 2 more holes using the Case as a template.

If you don't feel up to this task I can do it for you, no charge.
Case Kit.jpg
Case kit
Stage #1.jpg
Stage #1
Stage #2.jpg
Stage #2
Stage #3.jpg
Stage #3
Stage #4.jpg
Stage #4
Stage #5.jpg
Stage #5
Stage #6 and back view.jpg
Stage #6 and back view
Front view.jpg
Front view
Elk View Front.jpg
Electron view front
Elk View Back.jpg
Electron view Back
Dave H :D
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by 1024MAK » Thu Apr 12, 2018 6:31 pm

Nice 8) =D>

Mark
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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Sun Apr 15, 2018 4:44 pm

Pegasus Case:
Case Kit.jpg
Case Kit
Board Fitted.jpg
Board Fitted
Lid Fitted.jpg
Case Lid fited
Rear View.jpg
Back View
Rear View Plus 1.jpg
Back View Fitted Into Plus 1
Front View Plus 1.jpg
Front View Fitted Into Plus 1
Dave H :D
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by JonC » Sun Apr 15, 2018 5:42 pm

Very nice, those look really professional Dave.
Jon
Image

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by daveejhitchins » Sun Apr 15, 2018 7:54 pm

JonC wrote:Very nice, those look really professional Dave.
Thanks . . . I can look back now and - yes, it was worth the hassle - chuffed :D

Dave H :D
Parts: UM6502CE, GAL22V10D, GAL16V8D, AS6C62256A, TC514400AZ, WD1772, R6522, TMS27C512, AT28C256
Products: ARA II, ABR, ATI, AP6, MGC, AP5 . . .
For a price list, contact me at: Retro Hardware AT dave ej hitchins DOT plus DOT com

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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by 1024MAK » Sun Apr 15, 2018 9:13 pm

@Dave - blooming marvellous =D> =D> =D>

Mark
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Re: AP5, Pegasus/AP3-4/EUPURS Metal Case Design

Post by rharper » Mon Apr 16, 2018 8:01 pm

They look great =D> =D>
Anticipation is at maximum :!:
Ray :)
Raycomp

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