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Sectional printing & drilling holes

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(@zeroengineland)
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Joined: 4 years ago
Posts: 52
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I'm building two maps right now - a small one as practice and a dress rehearsal for a much larger one that has my home area.

  • Just take the TIF file from the FAA and print it exactly how you want.  I used uPrinting.com, and found their price was pretty good.  It seemed like it wasn't that much more than buying two pre-printed sectionals and trying to mount them together.  I could load the TIF at 300 dpi and set my crop box for what I wanted.  uPrinting asks for 1/8" of bleed at the edge of the pages, so if you want a side that's 30 inches, you just have that side be 30.25 (30 + 0.125*2).  They will give you a PDF preview with the cut line.  When you approve, it is sent to your door already cropped and rolled up.
  • I mounted my sectional on foam core board. To punch holes in the foam core for the LEDs, I used a Forstner bit in my hand drill.  The Forstner bit is designed to cut a flat hole.  It has a sharp edge that edges the circle, and a sharp ramp that flattens out the bottom.  There's a small spike to center.  Push the spike into the center of the airport and press slightly.  Make sure to have spoil material below it.  (With quarantine going strong, I had a ton of shipping boxes.)

Now I have to trace down the squirrelly ground on my breadboard.  To avoid trial and error with breadboard sockets, I bought a solderable breadboard, which is hopefully going to be a bit more solid once I solder everything in place.


   
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Mark Harris
(@markyharris)
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Joined: 5 years ago
Posts: 557
 

Sounds awesome! Please send pics of your build and certainly of the final products. We'd love to see them. 

Thanks - Mark


   
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(@zeroengineland)
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Joined: 4 years ago
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Well, I'm at an intermediate step.  There was nothing particularly interesting in the build log - I was punching holes with my Forstner bit, and I used grommets as a visual differentiator for an airport.  Everything is just hot glued into place.

I did have to chase down one squirrely problem with the electricals - my LA sectional uses one 25-light strand; the NorCal sectional required two strands because I wanted to cover down from Monterey in the south up to Tahoe in the north.  What I found is that I couldn't get solid enough breadboard connections in a regular breadboard, I had to use a solderable one.

Not hanging up yet, but they're working well enough to show a completed-ish build.  (I do have one question I'll be asking before I have finished products, and I can shoot closeup shots of some of the slightly novel aspects of my build.)

LA LiveSectional
SF LiveSectional

   
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Mark Harris
(@markyharris)
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Joined: 5 years ago
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Wow those are pretty. Nice job! Thanks for the pics. - Mark


   
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(@zeroengineland)
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Joined: 4 years ago
Posts: 52
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@markyharris I'll try to reverse engineer a build log for you.  I didn't take that many pictures along the way because I was using a combination of other people's work.  Rough steps so far (without pictures):

  1. Printing, which I outsourced.
  2. Attaching the sectional to foam core, which was spray-on adhesive.  I watched 3 or 4 photo tutorials, and did a solo version of this one from Adorama: https://www.youtube.com/watch?v=7wIfED-zZ7Q . I didn't buy the foam cutter tool, I just used a metal ruler to get it right on the theory that a slightly ragged edge from the utility knife would disappear into the frame.
  3. The Forstner bit punches through foam core easily, and it was only $7.
  4. I mounted LEDs with hot glue and grommets around them, as described here: https://led-sectional.kyleharmon.com/ (it's an Arduino-based project, the LiveSectional software seems to have more features)
  5. The frame was also as recommended in #4.  PictureFrames.com will custom make you a frame to 1/4" dimensions, so I made my sectional printouts to 1/4" increments.  The frame is super-deep and should easily contain the electronics.
  6. Lots of fiddling with breadboards to run 50 LEDs with auto-dimming.  I found that soldering is required.
  7. Clean everything up and hang it on the wall.

As soon as I clean up the wiring to my satisfaction, I'll post some pictures with the journey.


   
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