I had a few enquiries asking for more info on how this project, so here’s a circuit diagram. Hopefully this, along with the parts list and the notes that follow, should help you to get started.
The parts list is pretty small. I ordered the Optocouplers from Digi-Key, and picked up the Male DB9 while I was there. The parts are very cheap so you may as well buy a few spare ‘just in case’:
Qty Digi-Key Code Price Description
5 H11A817-ND $0.39 each OPTOCOUPLER TRANS-OUT 4-DIP
1 209ME-ND $0.87 each CONN DB9 MALE SOLDER CUP
5 1k ohm resistors, any old 1/4 watt or similar.
5 H11A817-ND $0.39 each OPTOCOUPLER TRANS-OUT 4-DIP
1 209ME-ND $0.87 each CONN DB9 MALE SOLDER CUP
5 1k ohm resistors, any old 1/4 watt or similar.
Other than that, I just used some wire and some solder. IDE drive ribbon cable works pretty well, it helps to mark the +ve cable with pen though, to help keep track when wiring. I didn’t use a circuit board- simply trimmed and soldered one pin of the optocouplers straight into the DB9 solder cups, and soldered the resistors straight onto the optocouplers. Helped to save a bit of space and let me fit everything back inside the controller case.
One thing to note about the optocoupler is that the resistance across pins 3 and 4 drops as the voltage across pins 1 and 2 increases. This means that you may need to put a lower value resistor in if the reistance across pins 3 and 4 doesn’t drop low enough to convince the controller that the button has been pressed. Be careful not to use too low a resistor though, and you’ll put too much current through LED between pins 1 and 2, and blow it. Radio Shack sells boxes of 1/4 and 1/8 watt resistors in common values for a few bucks.
I’d reccomend owning and using a multimeter when making this- you will want to identify the +5v and 0v USB pins (where the incoming USB cable connects to the controller circuit board). You’ll also want to know which side of the button pads are positive (+ve) and negative (-ve).
For the soldering, you’ll need a low-wattage iron with a new clean tip, and some thin solder. Make a firm mechanical join first (use croc clips or tape or something), then heat the join for a split second before touching the solder against it- the solder should flow into the join and make a good electrical connection.
That’s about it for now, feel free to email me at gt@gtpunch.com if you’ve any other questions.