
68
transformer,
are mounted on a small printed-
circuit board
measuring
about 4.5 by 2.5 inches.
The parts can be mounted
in
any order, but be sure
to install the diodes with
the right
orientation. Note
that the 1N5404 rectifier diodes (DI
-D4,
which
are rated
at 3 -A) are specified in the bridge
rectifier.
That's because
a high surge- current rating is required
(by
virtue
of the 4700µF /25
-WVDC capacitor).
The two 4700 -µF
capacitor,
CI
and
C2, must be oriented
correctly. Note
that Cl,
which
is
adjacent to diodes DI -D4
(the bridge rectifier), must
be rated at 25
WVDC.
The other
capacitor (C2) on the regulator output
can have a minimum
voltage
rating of 16 WVDC.
Don't use a 16 -WVDC
capacitor
at the output of
the rectifier -its
voltage
rating will be inade-
quate.
Finally,
install the 3- terminal regulator
(01) by bending its
leads
at right angles so that they
fit into the holes in the board.
The
regulator can then be bolted
to the PCB,
separated
from
the board surface
by its heatsink (as shown in
the photos).
The
Cabinet
One of
the best
things about this
project
is
that
you
can
build
your own cabinet.
We
made our
cabinet from dressed
radiata pine,
which
is relatively
cheap and much
easier to
work
than particleboard. Rather
than go for tricky miter
joints, we
elected to use butt joints because they are much
easier to make. Figure 4 shows
the dimensions of our cabinet.
Cut the timer to the dimensions shown, then
bevel the edges
using a plane or sanding
block. The panels
can
then
be
sanded to a smooth finish,
ready for assembly.
The baffle (front panel) board
is secured using cleats,
which
must be recessed in from
the front edge according
to
the thickness
of the baffle and either glued or screwed
in
position. Once the cleats have been installed,
the cabinet is
ready for
the final assembly.
It's up to you how
you
secure
the
various
panels. We
simply
glued them in position
using a
woodworking
glue.
Four large
C- clamps
were
used to hold the cabinet
together
while
the glue
was
drying. After
that, the cabinet
was
given a
coat of walnut
stain and three coats of satin silk
timber finish.
CLEATS
AROUND FRONT ,
ALL
DIMENSIONS IN INCHES
Fig.
4 -Shown here
are the dimensions of
our cabinet. Cut
the
timer to
the dimensions
shown, and bevel
the
edges using a
plane or
sanding block.
The
panels can then be sanded to a
smooth finish,
and assembled.
The
baffle board
is
secured using
cleats, which must be mounted recessed from the front
edge
according to the thickness
of
the
baffle and either
glued
or
screwed into
position.
PARTS
LIST
FOR
THE
IN -HOME
CAR STEREO
C1- 4700
-µF,
25
-WVDC
electrolytic
capacitor
C2- 4700
-1.1F,
16
-WVDC
electrolytic capacitor
D1- 04- 1N5404
3 -A,
400
-PIV
rectifier
diode
D5-D7-1N4002
1-A, 100
-PIV
rectifier
diode
T1- 117 -volt
primary, 15
-volt secondary,
stepdown
power transformer
ADDITIONAL
PARTS AND MATERIALS
Car radio
(see
text),
speakers,
grill
cloth,
printed-
circuit
or
perfboard
materials,
2 -way mains
terminal
block, 3-
conductor line
cord, mains
strain -relief (clamp
or
chassis mount),
enclosure, banana
plug, heatsink,
hook
-up wire,
solder lugs,
solder, hardware,
etc.
Incidentally,
if you
are using radiata pine for
the cabinet,
be
very
careful in handling
the timber.
Because it is soft, it is
easily marked; grubby
finger marks can be
a problem as
well.
Be
careful also not to get
excess glue on
what
will
be the
visible
surfaces of
the cabinet. If
all traces of glue are not
thoroughly removed
they
will
show up
as
white
spots
when
the stain is
applied.
It doesn't particularly
matter
what
you
use
for
the rear
panel.
We
used a piece of perforated
Masonite
we
had on
hand. The
baffle board can be made
from scrap
timber
since
it
will
later be covered by speaker
-grill cloth. It should be
at
least %a -inch
thick to provide
the necessary degree
of rigidity.
Before mounting
the baffle board, it will
be necessary to
make
cutouts to suit
your loudspeakers
and radio. The baffle
can then be covered with
a suitable fabric. We
recommend the
use of
either an acrylic scrim*
material (looks
like hessian *)
or a stretch fabric.
The fabric should be
pulled tight over the
baffle
and
stapled
in place.
The radio and speakers
can now be mounted
and the baffle.
fastened
to
the
cleats
using screws installed
from inside of the
cabinet
(see Fig. 4).
We
suggest
the use of standard oval
car radio speakers,
which
can be
either 6
x
4 inches
or
7
x
5 inches, which
have
good sensitivity
and will work
quite well without
any fancy
baffling in
the form of sealed
or bass -reflex
cabinetry. Do not
use high-
quality speakers -they
are usually far less sensitive
and require properly
-sealed or bass -reflex
cabinets if
they are
to provide
a decent audio output.
Hooking
Up the Radio
Connecting
the radio to the speakers,
the power supply,
and
an antenna is a fairly
easy task. Usually, it will
be
possible
to
identify
the various
leads from the manual, or
from
a chart pasted to the
top or bottom of the radio. If you
don't know what
the leads
are, you'll have to do some
detective work.
Figure 5 shows the hookup
for radios
with
built -in front/
back fader
controls. Such
configurations are normally
used
with
four
loudspeakers.
Connect the front and back outputs
together
as
shown.
If your radio
is a higher powered unit with
bridging outputs,
connect the speakers as shown
in Fig. 513.
For radios
that do not have fader
controls, the power
amplifier outputs
are connected directly to the loudspeakers.
Note that power switch
S I can be regarded as optional. If your
car radio has
a
built
-in digital clock or station memory,
the
switch
should be omitted
and the radio turned on and off
using its own power
switch.
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