Modular Electronics Control Panel – Build Part 5

Part 5 of my Modular Electronics Control Panel build has taken a while to post as I’ve been very busy working on the Control Panel and didn’t want to stop. I 3D printed 6 different custom brackets, created my own heat sink and halfway through the build, I swapped out the transformer for something that was better suited for this project.

Above you can see the 3D printed multimeter bracket that I used to mount the multimeter to the Control Panel. And to give the control panel more modular capability, I drilled 8 holes through bottom of the Control Panel and used threaded anchors from the bottom so now I could mount the upgradeable Power Distribution Board.

I 3D printed custom spacers to space out the Power Distribution Board and the bottom of the Control Panel. In the next picture you can see how I laid them out. I recycled an old bridge rectifier for this project but before I could use it I had to desolder the old circuit board remains. And then to mount the aluminum heat sink to the Power Distribution Board I 3D printed some special brackets.

In the above picture you can see the better suited power transformer, aluminum heat sink and the power distribution block all laid out and read to go. I used a green LED with a resistor as a temporary Power On light so I know when the the power is on during testing. I also wanted to add some fans to the Control Panel so I 3D printed a custom 60mm fan bracket for my initial aluminum heat sink tests.

On my initial tests even with a fan, a standard heat sink was not performing well, so I made my own heat sink out of 2″ aluminum square stock and some u channel aluminum stock. Then I 3D printed two special brackets to mount the aluminum heat sink to the fan at a 90 degree angle. Both these prints took over 5 and a half hours to print and then I had to print them again for the top part of the heat sink so it was a 3D printing day. The idea of the custom heat sink is to absorb as much heat as possible on the inside of the 2″ aluminum square stock where the fan could blow it out through the top.

Well after weeks of testing I was able to get a stable 41 degrees out of the LM7805 regulator with my custom heat sink on a really hot day of 29 degrees. The regulator was producing 1.25Amps which I don’t foresee myself needing this much current out of this 5V output, but even so I will know that this part of the Modular Electronics Control Panel will be able to handle it.


Check out the Video below which shows some great information about this part of the build.


To check out the current progress of this build, please check out my Modular Electronics Control Panel build page.

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