Radio Incident Command Kit (RICK on youtube) Dual band with KPC3 TNC

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Pelican 1450         1450PF panel frame          Astron SS-18 &  KPC3             only one fan used     Drill 2 holes to mount KPC to PS cover

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Drill 3 holes in SS18 to line up to fan holes to mount to front panel        .25" spade type  fuse holders & Switches for quick connect.

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solder DB9            SS18 to front panel with STAINLESS STEEL screws and NYLON STAINLESS lock nuts. 

wiring.jpg (455073 bytes)  WIRING DIAGRAM FOR THIS KIT.

Parts List:

QTY DESCRIPTION PART NUMBER VENDOR
4 FUSEHOLDER F012-ND DIGIKEY
4 FUSE AGC type ( you select values needed for your radio) VARIOUS SUPPLIERS
1 FAN 12v P9736-ND DIGIKEY
2 FINGER GUARD 80MM CR282-ND DIGIKEY
1 TOGGLE SWITCH SPDT EG4811-ND DIGIKEY
1 AC SOCKET PANEL MOUNT IEC C-14 CCM1401-ND DIGIKEY
1 AC POWER SWITCH 67-1917-ND DIGIKEY
3 DC POWER SWITCH 275-0712 RADIO SHACK
1 CASE MODEL 1450 VARIOUS SUPPLIERS
1 PANEL FRAME 1450PF VARIOUS SUPPLIERS
1 PK BLUE FEMALE INSULATED SPADE CRIMP CONNECTORS   VARIOUS SUPPLIERS
1 PK RED FEMALE INSULATED SPADE CRIMP CONNECTORS   VARIOUS SUPPLIERS
1PK SMALL TYWRAPS   VARIOUS SUPPLIERS
1 DB9 MALE OR FEMALE CONNECTOR YOUR PREFERANCE 276-1428 VARIOUS SUPPLIERS
1 ANDERSON CHASIS MOUNT (OPTIONAL) HS-4 POWER WERX
2 SETS ANDERSON POWER POLES   PP30 POWER WERX
1 AC LINE CORD NEMA 5-15P to IEC 320-C13 993-1039-ND VARIOUS SUPPLIERS
1 ASTRON POWER SUPPLY SS-18 VARIOUS SUPPLIERS
1 ICOM DUAL BAND TRANSCEIVER IC-208H HAM RADIO OUTLET
  MISC MOUNTING HARDWARE TAILORED TO YOUR KIT   HARDWARE STORE
1 MFJ TNC and ( data jack cable used old PS2 Mouse cord) KPC3+ HAM RADIO OUTLET

 

MOUNTING NOTES:

I chose to use existing holes in front panel at the 2 lower holes of the unused fan  mount and one corner of the active fan. This was in effort to minimize any additional holes drilled in panel as I plan on changing out the radio in the future but also plan on using the front panel for a lifetime. I didn't want to see a lot of bullet holes from a previous installation when reinstalling for a different radio at a later date.

Astron Power Supply model SS18 is held by 3 stainless steel screws with Nylon SS lock nuts for a solid mount to the panel. Solid Styrofoam can be placed in the the case between the KPC3+ and the inside bottom of the of the Pelican case to compensate for any torque on the opposite side of the SS18 that is not mounted to the panel unless you (drill additional holes). 

If you plan to ship your Radio Kit I would suggest you put the hard foam in the case such as from the exercise section of a Sporting goods store sold as work out blocks for exercise, it will appear as a solid foam block painted with a nice color paint. I would take the one my wife uses for exercise but I think she would figure it out pretty fast. I can't turn everything in the house to a ham project but it sure seems that way ... 

Radio bracket was trimmed down using a jig saw to fit on top of face plate to interior of pelican top lid. additional holes drilled in radio bracket to lower the radio to the surface of the face plate.

8/32" stainless hardware used for Power supply  and radio to face plate mounting.  6/32" stainless hardware used for KPC3 to Astron Cover mounting.

Pelican 1450 case used in this project with a Pelican 1450PF panel frame kit which mounts to the walls of the case and allows you to mount the face plate to the frame.

WIRING NOTES:

An AC computer power cord was cut short and used as a pig tail to plug to the back of the power supply then to the AC power switch through a AC fuse holder on to the IEC C14 AC chassis jack. You can then use the power cord for the power supply and plug it into the AC jack on the panel.

An old computer mouse plug was used as the Data plug to the back of the ICOM radio and wired to the TNC DB connector

A DB9 connector panel mount was used for the Computer port to the TNC wired to a plug in the back of the radio (all radios are different check your manual on how to hook up a TNC).

The Fan power was wired to the fused end of the DC Radio Fuse, I put some heat shrink over the wires and used a Tywrap with a hole mount to secure it from getting close to the fan blades. An option for another $1 would be to put a second fan grill inside the case to prevent wiring from getting to the blades.

Anderson  power pole RED/BLACK connector on a pig tail was used for External power input to the kit which is selected by "EXTERNAL" DC load switch on the panel using 14AWG red/black wire you see in the yellow sleeve in picture.

Anderson power pole RED/BLACK connector on a pig tail was used for "AUX" power output in case you want to power other equipment with the Astron SS18 power supply besides the Radio in the kit. 14AWG red/black in yellow sleeve in picture( must not overload the total load for the power supply)

All wiring used female spade lugs .25 inch type for quick wiring and replacement if needed.

Used 2 standard Yellow butt splices typically found in Electronics shops in the crimp section, or Hardware & automotive parts stores for connecting a lot of the DC plus and minus connections. (see wiring diagram)

"Do as you did, get what you got"  Lets all strive to be professionals in Communications.....   73 Rick KH7O         

kc7fpf1.jpg (228909 bytes)  kc7fpf2.jpg (213819 bytes)  kc7fpf3.jpg (228659 bytes)  kc7fpf4.jpg (194805 bytes)KC7PF Kevin made this nice tactical kit with LDG antenna tuner and Alinco Mobile using Anderson power pole chassis mount version and center mounted fan for under deck cooling. Nice job working with the Aluminum panel and the powerpoles. You can email Kevin if you have any questions on his kit. 

n1rfd1.jpg (100605 bytes) n1rfd2.jpg (59088 bytes)  n1rfd3.jpg (87112 bytes)  n1rfd4.jpg (92772 bytes)  N1RFD Michael built this "RICK" kit with a lot of features, pouches in the lid for accessories, used the West Marine power control panel with Anderson power pole blocks both on top and inside case, Switching power supply, low profile battery backup, forced air cooling, adapted use for the USB power, has a removable fan and light if needed. Used plyboard instead of aluminum panel for both panel face and equipment mounting interior.. Excellent job with diverse use.  I"m sure he will be building more kits, you can email Michael should you have any questions on his kit.

North Brevard Amateur Radio Club has posted many various design kits to give you more ideas click this link

ham_rig_004a.jpg (85519 bytes) K9LJB built up this portable full station setup click this link for his web site.