Turtle Sense communicator PVC housing assembly instructions - Revision history

Dave: Added a final step

2014-08-16T00:21:28Z

Added a final step

Sam: /* Final steps */

2014-08-15T22:43:11Z

Final steps

Sam: /* Final steps */ #Insert the set screws into the tapped holes with a 1/8" allen wrench.

2014-08-15T22:41:40Z

Final steps: #Insert the set screws into the tapped holes with a 1/8" allen wrench.

Sam: /* Gluing the pipe pieces */ set screws come later

2014-08-15T22:41:14Z

Gluing the pipe pieces: set screws come later

Sam: moved setscrews to the end

2014-08-15T22:40:10Z

moved setscrews to the end

Dave: Add wood block instructions

2014-08-15T00:44:00Z

Add wood block instructions

Dave: Finish gluing instructions.

2014-08-15T00:15:16Z

Finish gluing instructions.

Dave: Create page

2014-08-15T00:02:30Z

Create page

New page

==Overview==
The Communicator (Comm) unit housing is made out of standard PVC schedule 40 white pipe pieces and fittings. There is an upper section which houses the Comm PCB and phone board assembly, and a lower section which holds the battery pack. The pieces of each section are glued together with standard PVC pipe primer and PVC pipe cement. The two sections are attached to each other with a set screw, and another set screw holds the entire assembly onto the PVC pipe and concrete base (or "tower).
==Materials used==
* 3" Schedule 40 PVC pipe, about 9" total
* 3" Schedule 40 PVC shallow flat cap, qty 2
* 3" Schedule 40 PVC inside threaded pipe plug, qty 1
* 3" Schedule 40 PVC coupler, qty 1
* 3" Schedule 40 PVC cap, qty 1
* PVC pipe primer
* PVC pipe cement
* 91% isopropyl (rubbing) alcohol
* 1/4-20 x 1/4" allen set screw, qty 2

==Preparing the pipe pieces==
#Cut one piece of the PVC pipe 5 1/8" long, and another piece 3". A chop saw works best for this.
#Put a small chamfer on both ends of both pieces. A power sander or sanding by hand with #36 or #50 sandpaper works well.
#De-burr the sanded edges.
#If the Inside Threaded Pipe Plug does not fit loosely into the Coupler (very likely), sand off a little of the perimeter of the plug and de-burr.
#On the Coupler and one of the Shallow Flat Caps, drill a 3/16" hole about 3/4" from one end. These holes are for the set screws.
#Chamfer both holes, and then tap them with a 1/4-20 tap. You may wish to drill and tap the holes after the gluing is done, to avoid possibly gluing the wrong end.
#Using alcohol on a paper towel, clean the outer surface of both pipe pieces, and the gluing surfaces of all the fittings.

==Gluing the pipe pieces==
Work in a well ventilated area. The general procedure for gluing a joint is this:
#Check the fit of the pieces before gluing. The pieces should be able to go partway together.
#Apply primer to both surfaces of the joint.
#Within a minute or less, apply glue evenly and thoroughly to both surfaces of the joint.
#As quickly as possible, join the pieces firmly and hold them in place for about 30 seconds until the joint starts to set. A hammer may help seat the joint completely, but usually isn't necessary.
#The pieces can be handled in about a minute, but the glue takes up to 24 hours for full strength.

Following the "Mechanical - Side View" drawings, assemble the pieces together, one joint at a time:
#Glue the Inside Threaded Pipe Plug into one end of the 5 1/8" pipe piece. If any glue oozes out the edge, wipe it off or sand it off later.
#Glue the Coupler to the 5 1/8" pipe piece, on the same end as the plug in the previous step. Glue the half of the Coupler which does not have the tapped set screw hole.
#Glue the domed Cap onto the other end of the 5 1/8" pipe piece.
#Glue the two Shallow Flat Caps together, back to back. Use a flat surface with a vertical surface
#Glue the assembled Shallow Flat Caps to one end of the 3" pipe piece. Glue the half which does not have the tapped set screw hole.
#

@@ Line 21: / Line 21: @@
 #Following the "Mechanical - Side View" drawings, drill the holes in the center part of the Threaded Pipe Plug, and carefully de-burr them.
 #Following the "Mechanical - Side View" drawings, drill mounting holes in the two hardwood blocks.
 ==Gluing the pipe pieces==
@@ Line 41: / Line 42: @@
 #Chamfer both holes, and then tap them with a 1/4-20 tap.  Drill and tap the holes after the gluing is done, to avoid possibly gluing the wrong end.
 #Insert the set screws into the tapped holes with a 1/8" allen wrench.

@@ Line 38: / Line 38: @@
 ==Final steps==
-#On the Coupler and one of the Shallow Flat Caps, drill a 3/16" hole about 3/4" from one end.  These holes are for the set screws.
+#On the open end of the coupler and the open end of Shallow Flat Caps, drill a 3/16" hole about 3/4" from one end.  These holes are for the set screws.
 #Chamfer both holes, and then tap them with a 1/4-20 tap.  Drill and tap the holes after the gluing is done, to avoid possibly gluing the wrong end.
 #Insert the set screws into the tapped holes with a 1/8" allen wrench.

← Older revision		Revision as of 22:41, 15 August 2014
Line 40:		Line 40:
	#On the Coupler and one of the Shallow Flat Caps, drill a 3/16" hole about 3/4" from one end. These holes are for the set screws.		#On the Coupler and one of the Shallow Flat Caps, drill a 3/16" hole about 3/4" from one end. These holes are for the set screws.
	#Chamfer both holes, and then tap them with a 1/4-20 tap. Drill and tap the holes after the gluing is done, to avoid possibly gluing the wrong end.		#Chamfer both holes, and then tap them with a 1/4-20 tap. Drill and tap the holes after the gluing is done, to avoid possibly gluing the wrong end.
		+	#Insert the set screws into the tapped holes with a 1/8" allen wrench.

@@ Line 32: / Line 32: @@
 Following the "Mechanical - Side View" drawings, assemble the pieces together, one joint at a time:
 #Glue the Inside Threaded Pipe Plug into one end of the 5 1/8" pipe piece.  If any glue oozes out the edge, wipe it off or sand it off later.
-#Glue the Coupler to the 5 1/8" pipe piece, on the same end as the plug in the previous step.  Glue the half of the Coupler which does not have the tapped set screw hole.
+#Glue the Coupler to the 5 1/8" pipe piece, on the same end as the plug in the previous step.  G
 #Glue the domed Cap onto the other end of the 5 1/8" pipe piece.
 #Glue the two Shallow Flat Caps together, back to back.  Use a flat surface with a vertical surface behind it (such as a stair tread and riser), to align the caps when you glue them.
-#Glue the assembled Shallow Flat Caps to one end of the 3" pipe piece.  Glue the half which does not have the tapped set screw hole.
+#Glue the assembled Shallow Flat Caps to one end of the 3" pipe piece.
 ==Final steps==
 #On the Coupler and one of the Shallow Flat Caps, drill a 3/16" hole about 3/4" from one end.  These holes are for the set screws.
 #Chamfer both holes, and then tap them with a 1/4-20 tap.  Drill and tap the holes after the gluing is done, to avoid possibly gluing the wrong end.

@@ Line 13: / Line 13: @@
 * Hardwood blocks (such as Maple or Cherry) 3/8" x 4.2" x 1.1", qty 2
 ==Preparing the pipe pieces==
 #Cut one piece of the PVC pipe 5 1/8" long, and another piece 3".  A chop saw works best for this.
@@ Line 19: / Line 18: @@
 #De-burr the sanded edges.
 #If the Inside Threaded Pipe Plug does not fit loosely into the Coupler (very likely), sand off a little of the perimeter of the plug and de-burr.
 #Using alcohol on a paper towel, clean the outer surface of both pipe pieces, and the gluing surfaces of all the fittings.
 #Following the "Mechanical - Side View" drawings, drill the holes in the center part of the Threaded Pipe Plug, and carefully de-burr them.
@@ Line 40: / Line 37: @@
 #Glue the assembled Shallow Flat Caps to one end of the 3" pipe piece.  Glue the half which does not have the tapped set screw hole.
 #Insert the set screws into the tapped holes with a 1/8" allen wrench.

@@ Line 1: / Line 1: @@
 ==Overview==
-The Communicator (Comm) unit housing is made out of standard PVC schedule 40 white pipe pieces and fittings.  There is an upper section which houses the Comm PCB and phone board assembly, and a lower section which holds the battery pack.  The pieces of each section are glued together with standard PVC pipe primer and PVC pipe cement.  The two sections are attached to each other with a set screw, and another set screw holds the entire assembly onto the PVC pipe and concrete base (or "tower).
+The Communicator (Comm) unit housing is made out of standard PVC schedule 40 white pipe pieces and fittings.  There is an upper section which houses the Comm PCB and phone board assembly, and a lower section which holds the battery pack.  The pieces of each section are glued together with standard PVC pipe primer and PVC pipe cement.  The two sections are attached to each other with a set screw, and another set screw holds the entire assembly onto the PVC pipe and concrete base (or "tower).  There are also two wood support pieces which attach the Comm board to the PVC Inside Threaded Pipe Plug.
 ==Materials used==
 * 3" Schedule 40 PVC pipe, about 9" total
 * 3" Schedule 40 PVC shallow flat cap, qty 2
-* 3" Schedule 40 PVC inside threaded pipe plug, qty 1
+* 3" Schedule 40 PVC inside threaded pipe plug (a.k.a. cleanout plug), qty 1
 * 3" Schedule 40 PVC coupler, qty 1
 * 3" Schedule 40 PVC cap, qty 1
@@ Line 11: / Line 11: @@
 * 91% isopropyl (rubbing) alcohol
 * 1/4-20 x 1/4" allen set screw, qty 2
 ==Preparing the pipe pieces==
@@ Line 20: / Line 22: @@
 #Chamfer both holes, and then tap them with a 1/4-20 tap.  You may wish to drill and tap the holes after the gluing is done, to avoid possibly gluing the wrong end.
 #Using alcohol on a paper towel, clean the outer surface of both pipe pieces, and the gluing surfaces of all the fittings.
 ==Gluing the pipe pieces==