Hello, I am writing this build to show you guys how you can make an unique way to power on your computer. Instead of using a regular power button, I made a setup that required two toggle switches and a key switch in order to power on the computer.
The things I used for this are the following:
http://www.amazon.com/Hammond-1591DSBK-ABS-Project-Black/dp/B0002BENMI (Purchased 1)
http://www.amazon.com/Illuminated-Automotive-Toggle-Switch-Button/dp/B0060U92FS/ref=pd_bxgy_hi_text_y#productDetails (Purchased 2)
http://www.amazon.com/Momentary-Key-Switch-2-Keys/dp/B0002ZPBHK (Purchased 1)
http://www.amazon.com/Enercell-trade-High-Power-AC-Adapter/dp/B007ZL831K/ref=pd_sim_sbs_e_2?ie=UTF8&refRID=0Y6G85NCHPQRD0X30KSF (bought elsewhere but thats what I have)
http://www.lowes.com/pd_136033-12704-770307_4294722552__?productId=3363062&Ns=p_product_qty_sales_dollar|1&pl=1¤tURL=%3FNs%3Dp_product_qty_sales_dollar%7C1%26page%3D2&facetInfo=
http://www.lowes.com/ProductDisplay?partNumber=135682-12704-770314&langId=-1&storeId=10151&productId=3127719&catalogId=10051&cmRelshp=req&rel=nofollow&cId=PDIO1
I also used 18 gauge stranded black and red insulated copper wire for this
An optocoupler or mechanical relay (I am still working on getting that, will provide link later)
330 Ohm resistor
Two pin motherboard header
Some tools you will need:
- Drill with drill bit sizes or a step drill that can make 3/8 and 5/8 holes, the may have to be slightly bigger for the threads
- Soldering Iron and Solder, desoldering pump if you aren't that great at soldering and might mess up
- Wire strippers and cutters
- Pliers
- Wrenches (adjustable is best)
- Channel Locks (Completely optional, I didn't use them)
- Screwdriver
Also before I even begin I would like to give a huge thanks to Grrizz. He has helped me out a huge amount along the way and showed me great circuit diagrams and has given me advice on how to get this working.
You can check out the "behind the scenes" here: http://linustechtips.com/main/topic/282488-flip-switch-and-key-computer-start/
Now why did I do this, you may ask? I just wanted to do something fun, and this has always certainly seemed to fit that criteria for me. I'm not using it for any security purposes or anything of that sort.
Also take some time to know which pins on the toggle switches are positive, accessory, and ground. I mention these several times.
In this picture, the connector pin sitting horizontally on the right is ground, the pin just left to that is positive, and the pin on the very left is the accessory pin.
Step 1: Drill holes in the box (I did mine on the opposite side of the removable panel, mine went toggle switch, toggle switch, key switch)
Step 2: Mount the toggle switches
Step 3: Crimp 2 wires onto a terminal connector and bend the terminal connector to a 90 degree angle
Step 4: Place the each terminal connector on the ground of the two toggle switches
Step 5: Cut and crimp a wire that will go from the accessory pin of the first switch to the positive of the second switch (and bend those terminal connectors to a 90 degree angle
Step 6: Place the terminal connectors onto the corresponding places said in Step 5
It should look something like this:
Now after this, things become slightly more difficult, but certainly nothing too overwhelming.
Step 7: Cut off the end of the ac to dc wall plug
Step 8: Strip the two wires and know which one is negative and which is positive (on mine the dashed line cable is positive)
Now that you have you positive and negative from the wall plug, you can drill a hole in the box where you want the cables to be entering though.
Step 9: Push wires through the hole
Step 10: Crimp Connectors (you can use either connector type, depending on how many you have) I crimped these so that I could disconnect them in the event of failure
At this point, you are set up to make your connections to the positive from the first switch and to the ground power for the two switches and the optocoupler/relay
Step 11: Cut and crimp a cable for your positive terminal slot on your toggle switch (your terminal connector will have to be at a 90 degree angle like earlier in order for them to fit in the orientation I used
Step 12: Push the terminal connector onto the positive slot on the toggle switch
Step 13: Crimp the other side and connect it to the positive end of the positive wire of the wall plug that you crimped earlier
Now you will solder four wires together, yes four wires.
Step 14: Cut 4 wires, 2 in the appropriate length for the ground connections on the toggle switches, 1 for the ground connection for the optocoupler, and the other to connect to the ground wire on the wall adapter
Step 15: You can go ahead and crimp terminal connectors onto the two wires for the toggle switches and bend them 90 degrees
Step 16: Solder the 4 wires together, making sure that they are all firmly connected. Twisting them together will help this process.
Step 17: Take one of the two wires with no terminal connectors (because you crimped two of them) and crimp a terminal connector onto the end (remember to use the right one that will go other whichever one you used onto the wall adapter)
Step 18: Connect the terminal connector onto the ground terminal connector on the wall adapter
Let's take a step back and make sure that everything is correct. You will have your positive wire coming from your wall adapter going to the positive connector pin of the first toggle switch. The accessory pin of the first switch has a wire going to the positive connector pin of the second toggle switch. There is nothing on the accessory pin of the second toggle switch. Starting at the ground wire of the wall adapter, it connects to another wire that then splits into 3 other wires. Two of these are going to the ground connector pins of the two toggle switches. The last wire is going to nothing. Also the two switches should be mounted while the key switch is not in.
Now you will be soldering two wires onto the key switch.
Step 19: Cut a wire that will be going from your accessory pin on the second toggle switch to the key switch and crimp a connector to go over the accessory pin (and bend it 90 degrees to make it fit)
Step 20: Solder the other end of the wire onto the circular connector closest to the switch (you may have to put it in like how it will be to figure this out)
I put the wire inside the circular hole and soldered if from the inside, filling it up with solder to keep it in there
Step 21: Cut another wire (it will be going to your optocoupler/relay)
Step 22: Solder this one onto the other connector of the key switch
Step 23: Put the key switch in and connect the wire with the terminal connector onto the accessory pin of the toggle switch
Step 24: Feel free to tighten down all the nuts to the box securely
Before I say the next step I will say this: one of my LED's of my toggle switches went out. The other is working perfectly, so I don't know if it was something I did (like the wiring coming undone), but it went out very abruptly after working earlier when I was testing it. The LED's are supposed to like up with a range of 3.3V to 12V of power. I am using 5V, like I have planned through this guide.
Step 25: Plug in the wall adapter (MAKE SURE IT IS ON 5V) (although it shouldn't affect this)
Step 26: Turn on the switches and see the blue LED's!
This is just about where I am at. I have tested it with a 5V relay to turn on my computer, but I cannot permanently use that one, for I will be using that relay for other things.
Also thanks again to Grrizz for making this entire thing possible. He has been a great, rather, amazing help to bring this to life as said before.
I WILL continue to update this when I get my optocoupler. If I have any major holes in the steps or something doesn't make sense or if anyone has a question feel free to say it. I am sure there is some massive mistake in here.
I predict that there will be at least 10 mistakes or so, also if anyone sees a typo feel free to say it and I'll fix it!