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Discussion Starter #1
Being a broke college student with plenty of time to play with my bike, I started fabricating some electrical stuff a while back and figured I'd put up some pictures now that I've got myself all registered with this forum!

Preface:
I got frostbitten a bit and a few different bouts of hypothermia while driving between home and work on HWY-14 in Washington State. Any cold riders out there know that heated gear is well worth the extra effort and $$$'s. So, after spending a winter riding through the mountains with nothing for warmth on my hands but a pair of gloves I used for splitting wood, I decided it was time to purchase heated grips...

I soon found out that they're anything but cheap, so I ended up going with those crappy $20 kits that you just slap on under the stock grips. They worked okay for a while, but eventually I got sick of having to reach up and turn them off to prevent them from seriously burning my hands - only to turn them back on soon afterwards to keep from freezing! Pretty annoying while driving windy/winding mountain roads... So I looked up controllers.

Yikes, again. Spendy little suckers. Cheapest I could find (at the time) was around 65-80 bucks. So, being the tinkerer that I am, I did my research and just made my own out of a computer fan speed controller (Pulse Width Modulator, or PWM for those who don't know). I could have used a simple Potentiometer, but didn't want to have to worry about it crapping out on me in the mountains!

Anyways, from there I just started adding little things here and there.

One that I'm quite proud of is a cell phone headset that I turned into a stereo speaker system with full voice dial / voice direction gps navigation in my helmet. All for about 20 bucks.

Blah blah blah, here's links to a bunch of pictures! Enjoy!

Original Single PWM Box

Dual PWM's

Finished Dual PWM Box & Switch Panel

Switch Panel


P.S.,
I, quite literally, made most of this stuff from scrap stuff that I had laying around (bit of a pack rat...) and only spent monies when absolutely needed, as I am fairly poor, haha!:mrgreen:
 

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Discussion Starter #5 (Edited)
In Helmet Phone/Voice Dial/GPS Navigation/MUSIC!!

Okay, here's the set up. I have the ARAI XD helmet and an iPod Mini? i think it's called. Doesn't matter, you'll see it soon. Then, I have a Motorola Droid by Verizon. Couldn't afford the bill though, so now I have Cricket...

1. My helmet:
<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/IojmoX_p6lFDA1a4qWKFi4B11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/_t64ad4Hfflk/TX-KdR_jfaI/AAAAAAAAAKI/UbadstBYhYw/s800/IMG_20110315_083253.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table>


2. I took a couple old crappy headsets, you know, the ones that come free with the phone? And I cut em all up and re-soldered them back together to make it into an extension. This pic shows it with male ends, but the final product will have a female end to go from the helmet to the extension to the phone. Originally, I had it hardwired, but that was WAY too much of a pain to coil up 3 feet of wire into my helmet every time I took it off!:<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/WZtdO1E200J1S2ydvwJ144B11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/_t64ad4Hfflk/TX-KbItdPeI/AAAAAAAAAKE/yZRhBxECGlk/s800/IMG_20110315_083228.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table>

3. Got on ebay and found the cheapest speakers I could find, while keeping impedance, frequency range, and decent quality in mind. For the money (about 15 bucks) I found a set.<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/Ibamv_LQEzV20HWu2ErgFYB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/_t64ad4Hfflk/TX-Kko8oQKI/AAAAAAAAAKQ/-mbYMejMbfs/s800/IMG_20110315_083447.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table><table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/__NzWUjU5C7jJh-QPkNCV4B11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/_t64ad4Hfflk/TX-KkcVSO6I/AAAAAAAAAKM/4Y4a3x0IODc/s800/IMG_20110315_083503.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table><table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/Ed66Ey4U1AStZmlW8SpQ9YB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/_t64ad4Hfflk/TX-KmDZ88JI/AAAAAAAAAKU/TTAClB86qlM/s800/IMG_20110315_083526.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table>

4. The speakers were wired together with a stereo male 3.5mm on the end, so I just cut the earbuds off of another headset and soldered a stereo female 3.5mm onto it. Voila, speakers now connected to headset. THEN, just ran the wires behind all the padding inside the helmet so that the headset microphone was on the left side of my mouth. This way, I can reach up to push the "talk" button on the microphone without having to look away from the road.<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/KB55bdOLX7mhUO5wC2ydSoB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/_t64ad4Hfflk/TX-KwP_C2vI/AAAAAAAAAKo/-U2zPD6qTPo/s800/IMG_20110315_083556.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table><table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/LiY6A9XrNkUlHaEQRD7ywIB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/_t64ad4Hfflk/TX-Kvp2FogI/AAAAAAAAAKg/0GqcD5bdMaw/s800/IMG_20110315_083607.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table><table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/HcZB1aN_vXDdSO97TraqkIB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/_t64ad4Hfflk/TX-KwbXNmYI/AAAAAAAAAKk/i24i7mvbNRY/s800/IMG_20110315_083624.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table>

5. Since this helmet has the little neck flap wind thingy on the back of it, I just tucked away the bottom end of the headset into it, as the picture shows. This is the end that you would normally plug into a phone in order to make a call, listen to music, etc.<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/lkBH-mmt4zKZrc6wPKzCa4B11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/_t64ad4Hfflk/TX-K2wqrK9I/AAAAAAAAAKs/i2OPoRrljgI/s800/IMG_20110315_083645.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table>

6. So that iPod I was talking about, here it is!: <table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/TIKVbipXrpXg7eGNMxoF5oB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/_t64ad4Hfflk/TX-K4HDyUAI/AAAAAAAAAKw/bjkEjixIujw/s800/IMG_20110315_083659.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table>

7. Then, I figured I may as well rig up my phone to it right?!!? Why not, I mean, this way, I'd be able to have VOICE activated GPS Navigation on my freakin motorcycle!! Weeeeee! .... Strom! So I just zip tied the car mount that I got with the phone to the dash of the bike. It's not connected right now because I'm just about to do a full tune up on it and it was in the way, but here's where it was:<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/2Sp4OOvujLEpH0cknhyPNIB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/_t64ad4Hfflk/TX-KIRJwzfI/AAAAAAAAAJc/AFgX6xOmMEg/s800/IMG_20110315_083035.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table>

8. Now of course, I didn't have a 12v adapter yet, but using this super-computer phone while riding around really killed the battery, so I just put one in.<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/Ww-W1glrf5fo8hBSXzrVGIB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/_t64ad4Hfflk/TX-KSqGbnII/AAAAAAAAAJ0/-CZVK1v6zq0/s800/IMG_20110315_083109.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table><table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/ZUDEbNRngfX9fMSheolj-oB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/_t64ad4Hfflk/TX-KT628KVI/AAAAAAAAAJ4/64_W1RdROR8/s800/IMG_20110315_083134.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table>

9. After installation, I just ran the wire up the side of the gas tank and popped it up in front of the forks. I just wrapped it around that thing in the picture to hold it in place, due to the wire being springy.<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/t3iVx9ccEgqNUWCxEI5p7YB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/_t64ad4Hfflk/TX-KQVW-uwI/AAAAAAAAAJw/meIAsw9Lsu0/s800/IMG_20110315_083049.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table>

10. Hmm, well I think that's everything. Let me know if you have any questions, I'd be happy to help anyone else do this! It works great, sounds great(I wear earplugs while going on the highway and it still kicks at those high speeds with all the wind and traffic noise!), and doesn't look like hell! I'm all about doing what you can with what you got for as cheap as possible! The free-er the better-er. er.. Yup, anyways, I hope you enjoy!
 

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Thanks Jim. I was an electronics tech before moving into management (not that I've done much techie stuff in recent years) and I'm cheap.

You have no idea how cheap I am - so I'm always looking for ways I can use the accumulation of electronic stuff I have in the garage.

I picked up one of those little iPoddy things for $10 the other day - I thought it would be small enough to velcro or clip to my helmet rather than having the long lead down my neck (getting caught in my leather jacket's zipper).

I looked at shortening the earbud leads but, by heck, you'd need a fine tip on your iron! :)

A pair of speakers might be the way to go.

Thanks again.
 

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Discussion Starter #7
I looked at shortening the earbud leads but, by heck, you'd need a fine tip on your iron! :)

Thanks again.
Whaddya mean?! I couldn't afford one of those fancy-schmancy adjustable temperature dual tip billion dollar soldering stations, so I just made a temperature adjuster for my 260watt GUN. I use this BEAST for all my circuit board soldering! hahaha:<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/KtyZmvE70pZGzeAPieuh64B11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/_t64ad4Hfflk/TX_md-ubR1I/AAAAAAAAALU/sRxxGgusvbI/s800/IMG_20100828_151708.jpg" height="598" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table><table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/x1UoK4aU69I6z8zHufqoA4B11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/_t64ad4Hfflk/TX_mmSRODQI/AAAAAAAAALY/A7BfyZ7Y2wc/s800/IMG_20101127_101216.jpg" height="800" width="598" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table><table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/u-z5G8y_05yifXzfY2-YloB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/_t64ad4Hfflk/TX_ms3EdxTI/AAAAAAAAALs/Urp1fAiR07w/s800/IMG_20101127_101408.jpg" height="800" width="598" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table><table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/5Qvws94jZ1k8oqveEfKHOIB11fh4Jp_Zc71KEhdTtSk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/_t64ad4Hfflk/TX_mdcvU_EI/AAAAAAAAALM/7C8TNfpJiIE/s800/IMG_20101127_101206.jpg" height="800" width="598" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/deadheadawakened/Helmet?authkey=Gv1sRgCKTv7rDvz9DoRA&feat=embedwebsite">Helmet</a></td></tr></table>
 

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Discussion Starter #8
Thanks Jim. I was an electronics tech before moving into management (not that I've done much techie stuff in recent years) and I'm cheap.

You have no idea how cheap I am - so I'm always looking for ways I can use the accumulation of electronic stuff I have in the garage.

I picked up one of those little iPoddy things for $10 the other day - I thought it would be small enough to velcro or clip to my helmet rather than having the long lead down my neck (getting caught in my leather jacket's zipper).

I looked at shortening the earbud leads but, by heck, you'd need a fine tip on your iron! :)

A pair of speakers might be the way to go.

Thanks again.

Also, if you want/need help with ideas for this kind of stuff, it's pretty much what I do for fun! I'm essentially a "Fix-or-Fabricate-it" kinda person. I don't normally like to spend money for something I can make myself!

You're very welcome, glad you liked it!
 

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Cigarette lighter adapter

Okay, so I just bought a cig lighter adapter so I can charge my cell phone on the road. I have an SAE plug protruding from under the seat (for the battery tender). I also bought a wire with an SAE connector on each end.
My plan is to splice an SAE connector onto the cig lighter adapter. My question is, which wire goes to what??? The SAE wires are red (hot I assume) and white, the cig lighter wires are grey and white.
Thanks in advance!
liVeStrom
 

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Methinks I sense an enthusiastic EE or Physicist in the making. I suspect your impoverishment won't last too long. The extent of my experience and abilities with such things is to use my soldering iron to create lovely silver works of modern art on the floor around my bike sparing the wiring of any such contamination. :)
 

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And it tastes like chicken!

:hurray: Thank you for your kind encouragement and specific instructions. Shall I attempt this soldering operation barefooted then?:confused:
 

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Discussion Starter #13
Okay, so I just bought a cig lighter adapter so I can charge my cell phone on the road. I have an SAE plug protruding from under the seat (for the battery tender). I also bought a wire with an SAE connector on each end.
My plan is to splice an SAE connector onto the cig lighter adapter. My question is, which wire goes to what??? The SAE wires are red (hot I assume) and white, the cig lighter wires are grey and white.
Thanks in advance!
liVeStrom
The center of the cig lighter is always positive and the shell is negative, so I would wire in this order:

from cig lighter center (whichever color that is, CHECK FIRST),
to SAE red,
*to inline fuse*,
to battery power (red +).

From cig lighter SHELL (again, TEST for correct color),
to SAE white,
to battery ground (black -).

*****technically, you SHOULD use a fuse in there too. I HIGHLY recommend it, but it's your call.*****

If you don't have a volt/ohm meter, then just use a couple wires with a bulb and a battery or something like that.

I love cheap DIY projects with electronics, so let me know if you have any other questions!

PeAcE
 

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Make sure that you pick the correct end of the SAE connector to mount up on the bike.

Assuming you have an SAE connector that has both halves, you want to wire up the red wire to the hot side of the circuit, (positive). But you also want to make sure you don't create any possible issues when you do not have something plugged in to the SAE connector. So on your bike, mount up the end of the connector which has the red wire in the female part of the plug, and on your accessory, the red wire will be the male part of the plug. This prevents shorting to ground when the plug on the bike contacts the frame/tank etc.
 

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Discussion Starter #15
Make sure that you pick the correct end of the SAE connector to mount up on the bike.
It really is the LITTLE things... I've done it so many times that this stuff becomes natural and I hardly think about it, so thanks and good save!
 
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