My custom ignition LED, it lights up very bright!

It's done! An all new controller board to interface with the switches and LEDs I added to the tank top speedo housing. The controller board caters for the following:

• Fan override (ON).
• Full Fan Indication (with failsafe design).
• 3 x Hi-watt accessory switches (relay buffered).
• Each switch is an electronic toggle (click on, click again for off)
• All switches buffered for contact bounce and accidental double-click.
• One accessory switch already hooked up to new fog lamp.
• Power-on battery voltage display, with Green, Yellow and Red status (fully calibrated)
• Power-on ignition LED indicator (high intensity crystal Red LED on ignition housing)
• Voltage check and ignition LED trigger button on tank top.
• Voltage check and ignition LED circuit remains on for a settable time.
• Interfaces with alarm for super bright tank top alarm LED display.
• Custom-made shielded data cable runs from control panel.
• Fully fused and diode protected
• Switches on and off with ignition but accessories driven direct from battery.

Dimensions conform perfectly to the document compartment, toolbox still contains the stock tools.

It was tricky getting so much circuitry into such a small space, but with the help of dual IC chips I managed it. Three of the chips on the board contain two of the same ICs; two are dual flip-flops and the other is a dual high fidelity Op-Amp (which are used as comparators). Egads I'm a nerd! LOL

It's actually been a lot of fun designing and prototyping the circuit, then the printed circuit board, assembling it all, testing and calibrating it, installing it, and eventually, riding around with it! I realise this is an area not too many would be interested in, but if anyone is interested they can find here the full circuit diagram, PCB pattern etc. See below for a shot of the new board!

Click above for a closer look at the assembled PCB

The circuit is essentially designed around two separate circuits, one consists of four electronic toggles controlling relays, and the other is a timer, which feeds into a dual voltage comparator. One of the electronic toggles is set up slightly differently, as it is designed to to cater specifically for the fan override. The other toggles use solder pads and wire links to allow you to set the configuration of the relay. It can be easily set up in a myriad of ways through the soldering of links on the PCB. You can download the circuit below, which has been broken up into five separate section for clarity.

Click above to download the entire circuit as a GIF!

The PCB pattern can be downloaded below. This has been saved as a large GIF, you should be able to print out the pattern at the correct size using your graphics package, or failing that, any software which will allow you to embed an image. The image should be printed so that it is exactly 150mm wide. I have designed the image to be a top-down positive. This allows you to flip the image over when printed on a transparency, bringing the toner side closest to the PCB. This suits the Electrolube's Positive Photo Resist system. You could easily alter the included graphic by flipping or negativing the image to suit other systems.

Click above to download the PCB pattern as a GIF!

If anyone is interested in further details on the circuit, PCB design or related items, then please do not hesitate to ask. If there is enough demand I can always add more extensive details and instructions here on making your own controller board.

@ Sean Flanagan, 2004. All rights reserved.