FrontPanelExpress Templates

I have created templates using HPGL graphics to reduce the cost of panels from FrontPanelExpress.

1U basic panel template

2U basic panel template

This is a template for small 0.75" knobs.  I modify this design depending on the spacing of the controls.  I used this full design on my PSIM, without numeric legends on my Fixed Filter Bank, and without minor tic marks or numeric legends on my ComputerVoltageSource.

Small knob template

Module Power Consumption

Here is my spreadsheet with the power consumption of many purchased modules.  This information is either from the module specifications or was measured.

Module power consumption spreadsheet  updated

Patch Cables

I bought many of my patch cables through the custom orders that the late Larry Hendry organized.  I have found some others that I like.  Peavey makes a set of 6 molded color cables in 1' and 3' lengths.  I have only had a couple ever fail.  Calrad makes a set of 8 colored cables in 1', 2', 3', and 6' lengths.  The connectors are gold plated and I have never had one fail although they are difficult to fine.

Momentary and Toggle Switches

I do not use momentary pushbuttons as I find them awkward to use in the top and bottom cabinets.  I instead use momentary flatted-handle toggle switches to match the look and feel with all the other switches.

I have changed from NKK  to Mountain switches for lower cost. They have a limited selection and no momentary switches.

Lumix LEDs

I purchase a number of the Lumex LEDs and change them on most of my modules to match this color scheme.
    Green as general indicators and status such as the LFO rate on the MOTM-390
    Red for warning such as clipping on the Blacet TimeMachine
    Bi-color for indicating polarity such as on the MOTM-320
    Blue for MIDI status such as on my DJB-011 Ribbon Interface

The green, yellow, and red Lumix LEDs are available from Digikey.  The bi-color Lumix LEDs are available from Mouser.

I make my own MOTM-style bi-color and blue LEDs by grinding the top of a LED flat and fitting it into the Lumex plastic holder.

BI Technologies P260P Series Potentiometers

I originally used the Vishay/Spectrol 148/ 149 series potentiometers.  When the cost on these skyrocketed I switched to the 248 series.  As the cost of these skyrocketed I switched to BI Technologies P260P series potentiometers.  I couldn't find them in distribution in the USA so I purchased a minimum order quantity of 240 direct through Arrow Advantage.

Here's a visual comparison of the three different types of potentiometers.  The shaft on the P260P is a bit shorter so the knob is closer to the panel.  This is an advantage when using the smaller 3/4" knobs which have a shorter depth.  There is sufficient shaft length to space the knob out to match the 148/248 as shown on the far right.  The P260P has a good solid quality feel but is less stiff than the 148/248 controls.

I use chiclet PCBs from John Loffink to wire my panel mount potentiometers.  They're great.

Knobs

I continue to use the Tyco PKES90B1/4 for my standard knobs although they are getting very expensive.  Radio Shack makes a considerably less expensive molded heptagon knob.  It is slightly larger in diameter, has slightly wider flutes, and uses a slotted instead of allen setscrew.  They also make this same knob in a 3/4"" size that I use for all my smaller 1/4" shaft knobs.

Hardware

I use thin plastic washers to protect the panels for mounting and the additional thickness is an issue when using 1/4" screws to mounting rails.  I bought 5/16" screws which work perfect with the washers but they only come in quantity of 1000.

Other MOTM-Style Parts

Here are a variety of miscellaneous MOTM-style parts that I use.

Tempco Resistors

Digikey sells 3300PPM 5% 0805 SMD tempco resistors for about $0.55 each.  They have a variety of values from 27R to 1K8.  I have used these to make my own through-hole tempco resistors by soldering them to leads and encapsulating them in epoxy.

This is a flatted style for mounting between differential pairs.

I also made a round axial style for mounting on a PCB.  

I also used epoxy to directly mount the SMT resistors on the top of an IC. 

Sheet Metal Brackets

I use 5052 0.050" aluminum for my metal brackets.  I used to be able to shear and form them in the model shop at work.  I no longer have access and haven't been able to find a small brake or brake-shear combination that will handle this thickness (equivalent to 20 gauge mild steel).  I Instead made a wood jig to hold the sheet metal and provide a fence and guide for my Central Pneumatic air shears.  The air shears fit in between the two fences which guide it very well.  The jig can also be used to cut notches which many of my brackets use to clear front panel jacks and controls..

A good small box and pan brake is the Grizzly G0556 12", G0557 24", or the Shop Fox M1011 24".

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