Need some help with indicators painting job

[JMorrison]

7361


So far my plan is to cut acrylic crystal rectangles (4mm thickness), then I would drill a hole in the back and put a led there.

The last step is what I'm triyng to figure out: A "mask" to make the led lights only the text and not the whole surface.

The only thing that comes to my mind right now is to cover the piece with black paint and then to engrave the text using a tool like this...

7362


... removing the paint in the zones I want to let the light to pass through.
However I have serious doubts about the quality of the finished job while using this technique.

If you know an easier or more effective way please let me know.

[JMorrison]

Guys I'm really stucked here and thinking the method I mentioned above will not work.
Please I need some advices on how to deal with this.

[Joe Lavery]

The usual way is to paint the acrylic black and engrave the paint away with a CNC or a Laser. Unfortunately the method you suggest would not look very professional. :(
The only way to achieve a reasonable finish would be to print the legends on clear self adhesive film, (do a Google search for clear printable film). Stick that on top of your acrylic rectangles, paint the sides black and light it from behind with the appropriate colour. It would also be a good idea to spray a clear lacquer over the panels to stop the film lifting over time.

Hope that helps.
Joe

[jonesthesoftware]

a more expensive but very effective way is to get your local printer to to print the full set onto thick plastic film. Search the various cockpit websites and you can download a pdf which has the full set of legends which you can get printed, cut out and stick on
regards
geoff

[JMorrison]

The usual way is to paint the acrylic black and engrave the paint away with a CNC or a Laser. Unfortunately the method you suggest would not look very professional. :(
The only way to achieve a reasonable finish would be to print the legends on clear self adhesive film, (do a Google search for clear printable film). Stick that on top of your acrylic rectangles, paint the sides black and light it from behind with the appropriate colour. It would also be a good idea to spray a clear lacquer over the panels to stop the film lifting over time.

Hope that helps.
Joe

Thanks Joe, what CNC does mean?
Would a regular Inkjet printer work for this job?




a more expensive but very effective way is to get your local printer to to print the full set onto thick plastic film. Search the various cockpit websites and you can download a pdf which has the full set of legends which you can get printed, cut out and stick on
regards
geoff


Thank you Geoff, I did a lot of reasearch already and found nothing, that's why I posted here, but I will check again for that pdf you mentioned.

[Joe Lavery]

CNC means Computer Numerically Controlled, basically a computer driven router. In fact lots of machines these days can be computer controlled. A laser cutter is CNC controlled as well.

Yes, you can use an inkjet printer but you need the correct film for that, try a Google search for it. you may need to run it through the printer twice, or put two copies one on top of the other to stop light bleed through. It would take a some accuracy but can be done.

Joe.

[JMorrison]

Ok ty, I guess will be better to make it with professionals.
I just need to find a sheet with the labels.

[jonesthesoftware]

What aircraft are you making and what legends do you want? Annunciators or Korry switches or both?
I tried the inkjet printer and a laser printer but couldn't get opacity and also got lines where the printer advances the paper.

regards
geoff

[Joe Lavery]

I agree with Geoff on this, it can be done but it's not very effective. If you can afford it getting them printed professionally is by far thee better solution.

I have a Corel Draw file with all the annunciators for the 737 overhead if that's what you need.

Joe

[JMorrison]

What aircraft are you making and what legends do you want? Annunciators or Korry switches or both?


B738, and I need all them.



I have a Corel Draw file with all the annunciators for the 737 overhead if that's what you need.


I'll be grateful if you can share it.

[Joe Lavery]

No problem PM me your email address and I'll wizz em over... ;)

[JMorrison]

Sent, thanks in advance Joe. :p

[JMorrison]

Search the various cockpit websites and you can download a pdf which has the full set of legends which you can get printed, cut out and stick on


By chance, do you remember where you found this file?
I've been googling it the whole day and checking every related site I know, but still no luck.

[oldgreydog]

I know it's already been suggested, but I think the option of using an inkjet or better still a laser printer on OHP (overhead projector) film may do the job if you use a good enough quality printer and film. This would give greater control over content. If greater opacity is needed - print two sheets and double up.

[JMorrison]

Yes, I could also make it with the printing house, but I don't have anything to give them, I mean, Joe gave me the overhead part but I'm still missing all the rest.

[fordgt40]

Both Opencockpits and Flight Deck Solutions supply laser cut perspex face legends, generally with their own plastic holders. Why not ask them if they can supply just the legends. Opencockpits once sold me the gauge faces for the overhead rather than the complete articles. I have serious doubts whether you can print the legends AND block the light. Some other points are:-

Do not use ordinary round top LEDs, these have a light cone of circa 10-15deg - totally inadequate as you will end up with pin point lights shining through the legends.

Use two flat top leds (wide angle light cone) to avoid the above problem and get even coverage to the letters. Also, sand the rear face of the 4mm acrylic carrier to diffuse the light but do not embed the leds in this acrylic - they will be too close and give uneven lighting. Stick a 4mm acrylic carrier with the text legend on it to the front of the panel, with a further 4mm acrylic carrier with the leds to the rear of the panel

David

[JMorrison]

Hi David, importing electronics is a pain in the *** here in my country, you don't receive it in your house, it's retained in the airport so you need to hire a customs broker to clear your goods...it's very complicated stuff.

[jonesthesoftware]

Try this link for 100 737 annunciators legends and what they mean

Boeing 737-800 Annunciator Lights flashcards | Quizlet (http://quizlet.com/12376546/boeing-737-800-annunciator-lights-flash-cards/)

For the annunciators, you can make up a simple Word or text document or a graphics file using Word or Paintshop Pro or lots of other programs simply draw a black rectangle 1inch wide by 1/2 inch high and put the legends into the centre in white. The font is generally Futura lt BT about 3.5mm high. or the Korry switches a 1 inch square. Ask your local print shop what file formats they can accept to print these out with those dimensions.

Regards
Geoff

[JMorrison]

Thanks Geoff, must I print them at 100% opacity?
I mean, the text part.

[jonesthesoftware]

Check with your printer as you may need to put the text inclear or invisible, other wise yes 100% opacity for black and white
regards
geoff

[JMorrison]

Do not use ordinary round top LEDs, these have a light cone of circa 10-15deg - totally inadequate as you will end up with pin point lights shining through the legends.

Use two flat top leds (wide angle light cone) to avoid the above problem and get even coverage to the letters. Also, sand the rear face of the 4mm acrylic carrier to diffuse the light but do not embed the leds in this acrylic - they will be too close and give uneven lighting. Stick a 4mm acrylic carrier with the text legend on it to the front of the panel, with a further 4mm acrylic carrier with the leds to the rear of the panel



Ok I´m over this now and found the problem you mentioned.

I just made some tests with a 2000mcd round lens LED and the result was pretty bad, not only about the way the light showed, but also intensity was barely enough, even using a "small" resistor.

What is confusing me right now is looking catalogs about flat leds, they all appear with a luminous intensity of 3 or 5 mcd, that is 1/400 what I tried before...how can it be enough power?

Please enlighten me.

[fordgt40]

I use these with two leds per annunciator, other colours are available

30 Orange Flat Top 5mm Wide angle LED Free Resistors | eBay (http://www.ebay.co.uk/itm/30-Orange-Flat-Top-5mm-Wide-angle-LED-Free-Resistors-/120987479541?pt=UK_BOI_Electrical_Components_Supplies_ET&hash=item1c2b6a6df5)

Edit I assume that you are using clear acrylic, white opaque is not as good