Engravity Overhead Re-Wire

[Trevor Hale]

Hi Guys,

Ok, what I am going to attempt to do here is document the rewire of my Engravity Overhead.  The Equipment I had running the overhead was 2X Universal Joystick Controllers BU0836X 1 X Beta innovations Plasma Interface, and 2 Phidgets LED64 Cards.

The Overhead worked pretty well however I always had an issue with a flickering of the Blue Annunciators.  They seemed to have a "dataline" type signal superimposing itself upon the LED's.  Then after upgrading my Flight Sim computer I couldn't get 1/2 the switches to work properly anymore due to a short in the system.

It is very hard to wire the Overhead and still be able to backlight the panels.  Wiring can be very messy, and it very difficult to keep neat and tidy.  I have seen many builders do a bang up job on their overhead panels, and I want mine to look just as good.

Regardless, I am going to attempt to document the progress and display it here for everyone to witness.  I have determined that for ease of service and wiring. I will attach wires to every item in the overhead, and run the wires down the frame to the interface behind the MIP.

Anyway, here goes, and keep an eye on this thread for more progress.

Best regards,

Trev

[Bob Reed]

This will be fun to watch. I have wired one of these beasts and it is no joke! Good luck Trevor, I will be watching.

[warvet]

Ya no kidding Robert,
I wired my entired A340 Overhead and it was definitely a best lol

Tim
A340

[Trevor Hale]

Hey Guys, 

Just an update today.  Started on the Overhead..  I will add more when I get the next section Finished.  (Turning out way better the 3rd time is a charm) LOL

[Bob Reed]

Hey Trevor this looks great! Nice job!

[philb737]

Hey Trevor,
Nice job!!!!
It's your lucky day I'm upgrading to windows Vista 64 in the next few days(lucky for you), unfortunately,my brand new never used sim boards(FDT) are not compatible with windows Vista. I'm willing to give you a great deal if you're interested? The boards are a complete set and I can not sell them individually!!! I will take 10% off FDT's price list plus shipping.

1.USB Master Module
1.SIM-board USB Input Module (128 switches, 0 encoders, 8 potentiometers)
1.SIM-board USB Output Module (128 led outputs)
1.SIM-board USB Output Module (16 7-segment )
1.SIM-board USB MAXI Output Module(Top-Of-The-Range Module)

I'm also including the following items for free:
1 Crimping Tool,200 Crimp Contacts and Insulators,5 USB Cables,3 7-Segment Display Holder PCB, 12 Superb little white 7-segment display!!!

[jackpilot]

Trev, do you use telephone wire? looks like it..

[Trevor Hale]

It is actually 24AWG 4-Pair Stranded cable, used for wiring Card Access Readers, in commercial office buildings.

Just stuff I have laying around LOL

[Trevor Hale]

Hey Trevor,
Nice job!!!!
It's your lucky day I'm upgrading to windows Vista 64 in the next few days(lucky for you), unfortunately,my brand new never used sim boards(FDT) are not compatible with windows Vista. I'm willing to give you a great deal if you're interested? The boards are a complete set and I can not sell them individually!!! I will take 10% off FDT's price list plus shipping.

1.USB Master Module
1.SIM-board USB Input Module (128 switches, 0 encoders, 8 potentiometers)
1.SIM-board USB Output Module (128 led outputs)
1.SIM-board USB Output Module (16 7-segment )
1.SIM-board USB MAXI Output Module(Top-Of-The-Range Module)

I'm also including the following items for free:
1 Crimping Tool,200 Crimp Contacts and Insulators,5 USB Cables,3 7-Segment Display Holder PCB, 12 Superb little white 7-segment display!!!

Thanks Phil, that is a great deal, and would be an amazing setup, however I am running VISTA 32 and can't afford anything like that right now.  I have no use for the output boards cause I had the thing connected to my Phidgets LED64 cards.  The input boards would have been a good idea, except for the whole Vista thing,  I am going to use an EPIC board for now.  Thanks for the offer though.

That's very kind of you.

Trev

[jackpilot]

I have not yet started OVH wiring, what gauge do you recommend for wires, (bigger better, but not too big,  syndrome!!)

[Trevor Hale]

Actually to be honest I have wired 3 Overheads, and I would have to tell you what I have learned so far.

#1. what ever cable you go with make sure it is stranded.  Something like cat5 is ok, but if the wires wiggle too much they break off easily.

#2. I have wired with 18 AWG and it is way too big,  I would recommend 22, or 24 AWG wire, its easily good for an AMP at 12V without issue.  and I doubt you will be driving anything that powerful in your overhead.  If you need to have a switch controll some higher voltages or higher current, spend the couple of bucks and buy a relay.  use the low voltage wire to trip the relay and use the relay to switch the powerful stuff.

#3. Wire all your switches and LED's if you can the first time, you don't want to be opening and closing the overhead all the time every time you want to add something.

#4. last but not least, Because of Noise issues, I personally suggest you do not locate any interfaces in the same cavity as all the switches and led's.  I am running all the overhead connections down to the Capt Side wall and will install my interface boards there.

#5.  Take your time, there is lots to wire, and as you get frustrated I have founf that I rush,  when that happens I get up, grab a coffee and return and do some more.  Lots of breaks is importsnt.

#6.  Don't piss the wife off..  My living room floor looks like a bomb hit it, and the wife asked me what wiould happen if she cut some wires while I slept?  I sait it would be the crapper, she said, then get it the hell out of my living room..  LMFAO  I only have a week to complete it. 

That should do it

PS.  Try to keep all the wires out of the way of the backlighting, if you are using external backlighting like I am..  you need them out of the way so you don't get shadows.

Trev

[Trevor Hale]

Ok Guys,  So I still have the Overhead in my living room, but it is getting there..  Wife is beginning to loose patience with me, so I figured I had better take advantage of the Canadian Thanksgiving long weekend and finish it..

Anyway,  Almost done, Just the last section on the left and the light section to go..  so far there are 360 conductors, 45 cables with 8 conductors in each, and I figure I am 3/4's of the way there..

[Boeing Skunk Works]

That looks great Trevor. Really nice harnessing.

Mine started off very neat with the first dozen panels or so and now looks like a rat's nest since adding the rest of the panels over the years.

If I had any help around here to get it off of it's mounts from the ceiling I'd rewire mine too.

Mine weighs in the neighborhood of 60 pounds or so.

[dnoize]

excellent wiring job trevor !

Stef

[Trevor Hale]

Thanks Guys..  I found that wiring everything methodically did the trick..  Have all wires connected to everything in the first place allows for a neater wiring Job.

I just hope it all works without any hitches..

Trev

[ivar hestnes]

Very nice wiring Trevor. For sure you dont want to see mine, lol. Hope it works out when you connect it up again. But I am sure you have done your job well and it will work smooth.

[Trevor Hale]

  Ivar..  I hope it works when I reconnect it all too..  The method to which I attached all the wires, may prove difficult to find a problem if there is one, however.. I think I have it all sorted out.

I will be removing this from the Living Room in short order..  Looks Like I have it completed..

The Last thing I would like to see if I can do, is add the 7 Segments for the voltage and landing panels..

Then..  (I have it all sorted out )

Here is the completed images..

Trev

[when acting as a wave]

This looks great, very tidy!

My father's has a few intergral components fitted and wired (enough to operate a start-up etc.) but there's still a whole heap left to organise. Luckily it's readily able to be taken up and down without too much hassle though, and can be worked on from above with it still in position if necessary. There's also caution labels dangling off its corners to ensure no unsuspecting visitors knock themselves out on it, because there's currently no other overhead surrounds to warn them.

I apologise if any of my terminology doesn't makes no sense as well 

[Trevor Hale]

Ahh,  no your terminology sounds great to me..  I am sure his sim is fun to fly in.

Trev

[PittsburghLever]

Out of curiosity, Trevor, how much does the wired overhead weigh? I am trying to get a feel for how sturdy my shell construction has to be.

Thanks,
Boaz

[Trevor Hale]

Hey Boaz,

Lets just say the cabling weighs way more then the overhead..  I would say 25lbs give or take.. for just the overhead.  but if I was to hold on to all the cabling and the overhead, I would say all together over 50 lbs.

[Trevor Hale]

Hey All,

Final update before I reinstall the overhead today!  Just completed my Power Panel.  Lots of work, but I am very pleased..

[NAX228]

I see you only got two digits in the lower center field of the powerpanel (AC AMPS), but my APU easily goes past 100Amps, needing 3 digits.
That being said, I have all the parts lying in boxes ready to be mounted and I to have only 2 digits for AC AMPS. bummer, but I got a Dremel.

Really nice work. I've got a lot of the CAT5 cables and it likes, but seems like the air in the cables takes up a lot of space. I can only dream of getting my work as tidy as yours...

[Trevor Hale]

Thanks Nax,  I have to take more photo's with the wires connected to the interface..  Although the cabling is neat and tidy, trying to troubleshoot a problem would be a serious undertaking.  I have to admit I couldn't afford a real Power panel that reads the actual voltages..  so Mine is just a dummy hardwired to those numbers..  for example..  My APU may not be running but it will still read the 94 amps.  Although, The battery would have to be on, for the power panel to even light up.  (Seems silly) but for now, it will work.  More eye candy then nothing.

Thanks for the nice comments.

Trev

[jackpilot]

Actualy you can get some functionnality by having a "0" digit lighting up when needed if you add some separate circuit gates driven by the two rotaries.
JP