*This document was copied and updated with images from BitCal-B*

Make sure you read ALL the instructions at least once before even heading out to the store. Then re-read them. A small goof can lead to a LOT of extra heartache.

Parts List
In all possible cases I've included the Radio Shack Stock # for reference.
The first two parts make up the adapter that plugs into the wall:


3V 700mA Power Adapter (273-1756)
* Adaptaplug "N" 5.5mm OD x 2.5mm ID (273-1717) Note that this comes free with purchase of the Power Adapter

 

These are the parts that you have to put together:

3 x 2 x 1 in. Project Enclosure (270-1801)
   
Coaxial DC Power Jack 5.5mm OD x 2.5mm ID (274-1576A)
   
PC Board Toggle Switch (275-645A)
*Note that they have an identical switch not for PCs that also works and has convenient holes in the contacts for soldering.
   
5mm Blue LED 3.7V 20mA (276-316)
* Note any LED with a rating of over 3V will work; pick a pretty one! 		?
   
Hook-Up Wire (278-1221)
* Note that if you already have wire, this is unecessary, but I recommend Solid rather than Braided wire.
   
Bit Char-G Power Platform (N/A)
* Note that any properly spaced metal contacts will work, but if you have an extra controller because you now have a 4-Channel one… 		 

Tools List
These are the tools you'll need for the project:

The Plan

Cicuit Diagram
This plan shows where all the connections for the wiring go, and roughly how they fit into the box.

Step 1: Power Jack
The Power Jack is the only component that installs from the outside, and thus needs to be dealt with first.

  1. With the top of the Project Box on, measure and mark the center of one of the 2 x 1 in. sides; this will be the "bottom."
  2. On the opposite 2 x 1 in. side (top), mark and drill two holes for the LED and Toggle Switch. Make sure that they are well clear of the lip of the Project Enclosure lid when closed.
  3. Select a bit very slightly smaller than the OD of the threads of the Power Jack and drill a hole in the box.
  4. Solder a red wire (approx. 3 in.) to the center contact (positive) of the Jack.
  5. Solder two black wires: 3 in. and 1 ½ in. to the outside post (negative) of the Jack.
  6. Screw the Power Jack into place and secure with its retaining nut.

Step 2: Solder Fest
Make sure that you have good soldering connections, melting your solder onto the bits and not onto the tip of the iron. If you need help on soldering, ask an old hand before starting. Better to make a good connection the first time than have to go back and redo it!

  1. Solder the 3 in. red wire from the Power Jack onto one terminal of the Toggle Switch.
  2. Solder 2 new pieces of red wire (both 1 ½ in.) to the other terminal of the Toggle Switch.
  3. Solder the other end of one of the new pieces to the long (positive) terminal of the LED; I strongly suggest cutting the lead down AFTER you've identified and marked it.
  4. Solder the other piece to the positive contact of the Char-G Power Platform.
  5. Solder the 3in. black wire from the Power Jack to the short (negative) terminal of the LED using the same technique as above.
  6. Solder the 1 ½ in. black wire from the Power Jack to the negative contact of the Char-G Power Platform.
  7. All of the wiring should be connected and complete. Test it by plugging in the Power Adapter; if the LED comes on, odds are it's good. Further test it by charging a car. NOTE: the LED will be OFF while the car is charging.

Step 3: The Lid
To make a box that looks cool in addition to being functional, this is one of the most important parts to get right, so go slow; maesure twice and cut once!
  1. Measure and mark the center of the lid.
  2. Mark the openning for the Power Platform (18mm x 28mm).
  3. Drill pilot holes for your saw and cut out the openning.
  4. Mark and file out two 1mm x 5mm notches for the "grabber arms" of the platform.
  5. Test fit the platform and make minor adjustments by filing or sandpaper till you're happy with the fit.

Step 4: Final Assembly
This is the easy part!

  1. Install the LED into the box, use a bit of epoxy around the lower lip of the LED to keep it securely in place.
  2. Install the Toggle Switch into the box and secure it with its retaining nut.
  3. Lightly score the Lid and Power Platform where they will touch (this makes the glue hold better), and epoxy it into place.
  4. Wait far longer than recommended setting time of the epoxy. Nothing is worse than getting too eager and having to redo the previous step.
  5. Use the screws provided to secure the Lid to the Project Enclosure.
  6. You're DONE!

With minor variations in placing the LED and switch, it should look something like this:

Charger Bottom Charger View