GRJ's Original DIY Constant Current PAX Car Lighting Module Files

@stan2004 posted:

By my reckoning, your linked youtube video shows "just" a capacitor and a bridge-rectifier (not a voltage regulator).

To each his own but I think the photo (clipped from your video link) is RIDiCULOUSLY bright!  GRJ's module allows brightness control...amongst many other benefits.

Full disclosure, I have absolutely no business relationship to GRJ's goings ons and arguably we disagree here on OGR more than we agree!   Also, you get support from fellow OGR participants with his module which is absolutely priceless IMHO.

Stan, I suspect he's also driving the LED's way past their rated 12VDC spec.  He has a bridge rectifier and a pretty large 4700uf cap, so I'm guessing unless the voltage on the tracks is in the 9-10 VAC range, the output DC is way over 12V.

Live and Learn though John, redoing a batch would cure the desire for too simple.

I am hoping to actually be running MY trains by this time next year, the new house is likely 3 months from completion and I can begin to finish the packed pax cars with your LED boards. I have been doing club trains for 13 months as wait for my place to be finished. I think I can build a board in like 5 minutes now, so production times will not be an issue.

Finding the boxes with all of MY components will be a treasure hunt for sure.

Gunrunnerjohn, do you provide a completed assembly of your PCB?

Jon

Get them here.

@Rod Stewart posted:

Another option is OshPark domestically. Their price per board is higher, but if you only need a few that would work. I beleive their price is about $1.25 a board in batches of 3. Again as grj says you upload the gerber zip file to their site and go from there.

If you only need 10 or 20 boards I can mail them to you inexpensively. Shoot me an email if interested. I can also help with placing a board order for you for delivery to your address if needed.

Rod

Hi Rod, being new to the Forum I am not sure how to send you a email. Would like to ask a couple questions. So I need some guidance on how to shoot you a email. Thanks for your help.

@DCS213 posted:

Hi Rod, being new to the Forum I am not sure how to send you a email. Would like to ask a couple questions. So I need some guidance on how to shoot you a email. Thanks for your help.

Click on the profile name, the public profile will pop up, any public email address will be there.

For example...  Email obscured for privacy concerns.

Posting the latest update to my lighting installation tips, in pdf format in case it's helpful to anyone.

PLEASE NOTE: There is a revised version 1.2 of this installation tips file attached several posts farther down!

Rod

Wow, Rod!  That is really nice.  Thank you.

Rod, Have either you or GRJ thought of offering complete DIY kits of these modules? Complete kits (less LED strips) including: boards, parts  and an instruction sheet with an illustrated wiring diagram? Perhaps in a minimum of 12 or even 20 kits per package? It would be perfect for those of us who enjoy assembling, but HATE ordering through the mazes of DigiKey or Mouser catalogs, or, worse yet online from China!

@Rod Stewart posted:

Posting the latest update to my lighting installation tips, in pdf format in case it's helpful to anyone.

Rod

Thanks Rod,

That pdf is really great. 

John

@Rod Stewart posted:

Posting the latest update to my lighting installation tips, in pdf format in case it's helpful to anyone.

Rod

Thanks Rod for the great set of instructions.   Greatly appreciated.

@Rod Stewart posted:

Posting the latest update to my lighting installation tips, in pdf format in case it's helpful to anyone.

Rod

Thanks Rod for all your help. It was great talking to you. Can't wait to dive into this little project. Again Thank You

@Rod Stewart posted:

Posting the latest update to my lighting installation tips, in pdf format in case it's helpful to anyone.

Rod

Great tips, Rod.  Thanks.

Bob

Thanks Rod, great information & like you said, A picture is worth a Thousand Word. Can't wait to dive into this little project. Thank you for your help & it was great talking with you.

Rod, very well done.  I may have missed it but where does the LED board on page 6 come from?  Seems I saw it in a previous post but can't find it.  Thanks.

@hokie71 posted:

Rod, very well done.  I may have missed it but where does the LED board on page 6 come from?  Seems I saw it in a previous post but can't find it.  Thanks.

I should have probably elaborated on that point. I posted those boards in a topic back a few months ago, and they really make obs car marker lighting slick.

I have the bare boards available and I charge $.50 a piece for them. I can also make the gerbers available for anyone who wants to order them from OshPark or wherever.

I should add here that several of these boards can be shipped very inexpensively in a regular envelope marked “Non-machinable”. I have shipped them this way a couple of times.

Rpd

Following this thread over time, brings a lot of information about the DIY passenger car lighting module.  Many of you know that I have built and used this module for all my passenger cars, thus developing a modest amount of experience in the build.  To that end, I have put together a short instruction sheet to demonstrate the relative ease in putting together this very useful lighting PCB.  Please use it for help in not only the PCB build, but also to see for yourself if it is something you may want to try.  The instructions are basic, if I am not clear in the instructions, or, you have any questions, please do not hesitate to shoot me an email(in profile)  Give it a try!!

@TedW posted:

Following this thread over time, brings a lot of information about the DIY passenger car lighting module.  Many of you know that I have built and used this module for all my passenger cars, thus developing a modest amount of experience in the build.  To that end, I have put together a short instruction sheet to demonstrate the relative ease in putting together this very useful lighting PCB.  Please use it for help in not only the PCB build, but also to see for yourself if it is something you may want to try.  The instructions are basic, if I am not clear in the instructions, or, you have any questions, please do not hesitate to shoot me an email(in profile)  Give it a try!!

@TedW sent me this file a couple of years ago. As a complete novice at soldering and PCB building, it was a perfect stimulus to get me going. A must read for anyone thinking of doing this. Thanks @TedW.

Bob

Thanks for doing that Ted.  Truly appreciated.

John

@Rod Stewart posted:

Posting the latest update to my lighting installation tips, in pdf format in case it's helpful to anyone.

Rod

A gentleman who recently bought some builtup modules from me had a few questions regarding AC wiring and led strip attachment. So I figured it would be a good idea to clarify things a bit in the installation tips document; revised and pdf copy attached below.

Rod

@Bob "O" posted:

@TedW sent me this file a couple of years ago. As a complete novice at soldering and PCB building, it was a perfect stimulus to get me going. A must read for anyone thinking of doing this. Thanks @TedW.

Bob

@Rod Stewart posted:

A gentleman who recently bought some builtup modules from me had a few questions regarding AC wiring and led strip attachment. So I figured it would be a good idea to clarify things a bit in the installation tips document; revised and pdf copy attached below.

Rod

Props to @TedW and @Rod Stewart for excellent compilations and photos for LED lighting of passenger cars. 

I particularly appreciate the details on lighting the observation car.  Thanks guys.

Thank you to everyone for your help. Completed my first aluminum passenger car. Everything worked out perfect. only 7 more to go.

I probably missed it but are the Gerber files for the observation car board posted somewhere? Thanks.

@hokie71 posted:

I probably missed it but are the Gerber files for the observation car board posted somewhere? Thanks.

I can't recall if I posted the gerbers in the original topic, but here is the file attached below.

The boards are 31 x 55 mm; so if you order them from OSHPark they are going to run about $4.50 a piece in lots of 3. I ordered a large batch from offshore and I can sell them for $.50 each plus postage, which would be quite reasonable.

Here is a pic of the board installed and connected to the roof led strip lighting. Pretty straightforward.

Rod

@Rod Stewart, check your email, please.  I'd like some boards.

@Pingman posted:

@Rod Stewart, check your email, please.  I'd like some boards.

Same here, thanks Rod.

@modeltrainsparts posted:

Rod, Have either you or GRJ thought of offering complete DIY kits of these modules? Complete kits (less LED strips) including: boards, parts  and an instruction sheet with an illustrated wiring diagram? Perhaps in a minimum of 12 or even 20 kits per package? It would be perfect for those of us who enjoy assembling, but HATE ordering through the mazes of DigiKey or Mouser catalogs, or, worse yet online from China!

Since Jasper added this post I have had a couple of other off-forum requests for these kits. I now have all parts on hand for a limited number of kits if anyone else is interested. Each kit includes board, all necessary components, and a male-female pair of JST PH 1.25 connector pigtails also. The latter makes connections to the led strip within the car easy, and allows for future removal of the car roof. The kit is all thru-hole construction and assembly is quite easy. After you have done a couple it takes only a few minutes to assemble each module. The DIY Lighting pcb Build file provided earlier in this thread by Ted Wilson is an excellent reference for board assembly. My installation tips pdf also attached above will guide you as to how to install them in the passenger cars.

Please note these kits are intended for the DIY enthusiast. You will need basic tools and soldering skills. All parts needed for board assembly are included. You will also need to order some strip led reels; 12V 3528, 5m x 300 leds per reel, in either warm white or white, your choice. These are readily available on ebay, AliExpress, and Amazon for a few dollars each. One reel will usually do two 5 or 6 car passenger sets.

Kit price is only $4.00 each, and I can supply lots of 6, 12, or 20. Shipping will be by USPS priority $10.00 flat rate box (to anywhere in the lower US) regardless of quantity, and includes tracking and basic insurance. If you are interested please shoot me an email, address in my profile.

Here is a pic of several finished modules:

Rod

I have another pre-pack of 6 kits and one of 12 kits ready for immediate shipping if anyone else is interested?

And as a little bonus I am including one observation car led board with every six kits just to make lighting the observation car a little easier.

Rod

Many thanks, Rod!!

Looks like I've created a monster!

@gunrunnerjohn posted:

Looks like I've created a monster!

Heh heh heh........

@Mark Boyce posted:

Many thanks, Rod!!

No worries Mark, and thanks for jumping in. Enjoy your kit building!

Rod

The kits are a great idea, @Rod Stewart.  And I look forward to receiving the obs car boards.

I have had a couple of requests for a wiring diagram for installing these modules inside passenger cars. The wiring connections are not at all difficult, but for those who are feeling a little unsure this diagram should point the way.

Updated version posted below.

Rod

@Rod Stewart posted:

I have had a couple of requests for a wiring diagram for installing these modules inside passenger cars. The wiring connections are not at all difficult, but for those who are feeling a little unsure this diagram should point the way.

I hasten to point out, the JST PH connectors are 2.0mm pitch, not 1.25mm.

Here is an option to help simplify the AC part on Rod's sketch above.   If you have railking cars (and maybe others depending on the old incandescent lighting), you may be able to simplify the AC wiring by reusing the old socket and bulb holder.  This keeps you from taking out the seats, disconnecting the wiring to the truck pickups, and makes life a ton simpler.

@gunrunnerjohn posted:

I hasten to point out, the JST PH connectors are 2.0mm pitch, not 1.25mm.

Actually John the ones I typically use are the 1.25 pitch per the ebay listing below:

They are really tiny and well suited to passenger car led work. I solder one to the DC outputs on the board, and the other to one end of the strip leds, just like in my rather crude wiring connection diagram. Makes it easy to separate the roof from the car body if you ever need to.

Rod

@Rod Stewart posted:

Actually John the ones I typically use are the 1.25 pitch per the ebay listing below:

My point Rod is that JST-PH connector are 2.0mm pitch!  If you use that description, you're the only one that can find them as you are using an incorrect description.

Updated version of the wiring connection pdf file attached 5 posts up. It has a few minor tweaks plus the reference to "PH" is deleted from the JST connectors. There, that should make everyone happy heh heh!

Rod

@hokie71 posted:

Here is an option to help simplify the AC part on Rod's sketch above.   If you have railking cars (and maybe others depending on the old incandescent lighting), you may be able to simplify the AC wiring by reusing the old socket and bulb holder.  This keeps you from taking out the seats, disconnecting the wiring to the truck pickups, and makes life a ton simpler.

Hokie 71; this is a very neat idea IMO. I would have never thought of that! I have never had an issue with removing excess wires from the underfloor, nor do I disconnect anything from the trucks, but your idea should help to save time converting cars equipped with these light sockets. I like it!

Since I like to locate the module either in the vestibule area, or a restroom, I would likely still put MF pigtails in the DC module-to-led strip wires, and hardwire the re-used light socket to the module AC pads. But that's just me, a personal preference thing.

Question: For the other original car lights, do you just clip their wires flush to the seat frame? Or?

Rod