to the buzzer switch.
3. Using six #6-32 x 1” screws, 1/2 inch nylon
spacers, and #6 tooth washers and nuts, fasten
the PCB to the front panel.
4. Fasten the toggle power switch, toggle
buzzer switch, and push button reset switch to
the front panel. Don’t use the split washer that
comes with the push button switch. Set the front
panel and PCB aside.
Quiz Box Construction
The quiz box is constructed from 1/4 inch
plywood. A 3/8 inch divider separates the hand
switch storage compartment from the battery and
electronics area. Note the four inch dimension for
the height of the box. Since the box cover is
about 1-3/4 inches in depth, I recommend that
you build a box 10-1/2 x 11-1/4 x 5-3/4. Using
your table saw set to four inches, cut the cover
away from the rest of the box. You will then have
a cover that is 10-1/2 x 11-1/4 x 1-3/4 minus the
saw cut. This way, the cover should fit the box
(mark which way the cover goes).
The divider is made of 10 x 3-3/4 x 3/8 inch
plywood. A 5/16 inch diameter hole is drilled to
make way for the 12-wire cable. There are two
1/2 x 1/2 x 10 inch pine boards glued to the box
and divider 3/8 inches down from the top of the
box that will hold the front panel in place.
Remember to cut the opening for the D-SUB connectors
on both the right and left sides of the box. The box and lid
are covered with blue vinyl cloth. Look at Photos 1 and 2
to see how the handle, hinges, and locking hardware are
mounted on the lid and box. The hinges are the kind that
separate so the cover can be removed.
■ PHOTO 6.
■ PHOTO 7.
D-sub Connectors and Cables
The Photo 6 inset shows that the male D-SUB connector has four colored wires attached to it. The female
D-SUB connector has only three colored wires. I use 10
inches of 10-conductor ribbon cable, separating four
conductors away from three conductors. Using Figure 5 as
a guide, solder wires to pins 1, 3, 4, and 5 of the male
connector. Make a note of the color code and pin numbers. I put the lightest color on pin 1. Feed the four wires
through the left hole on the box and secure the connector
with two #4 x 3/4” Phillips pan head sheet metal screws.
The female connector has to have pins 4 and 5
connected together with one wire. I use the darkest color
here. Pins 3 and 1 are connected next. Note that pin 2 is
not used in either connector. Again, make a note of the
color code and pin numbers. Feed the three wires through
the right hole on the box and secure the connector
with two #4 screws. Set the quiz box aside. The D-SUB
connector wires will be connected to the front panel later.
12-Conductor Wire and
Remove the distribution box cover and note the ribs
used to hold PCBs. Remove these ribs using a wood
chisel. Next, study Photo 7 and the diagram in Figure 8.
Drill a 9/32 inch hole at one end for the 12-conductor
cable. Using a 15/64 inch drill, drill five holes on each side
3/4 inches apart to receive the RCA jacks. Thread the
jacks through the hole for a snug fit. The jack comes with
a solder lug that is to be positioned straight up. Twist the
solder lug about 45 degrees so that a nine inch long bare
wire can be passed through each lug. A #18 or #22 wire
will do. Solder all connections except jacks 5 and 6.
August 2009 53