CHAPTER 14

MAKING THE IGNITION CONTROLLER

The ignition controller is a remote control device that provides the voltage necessary to start the rocket engine. It allows the rocket to be launched from a safe distance with minimal equipment.

MAKING THE IGNITION CONTROLLER

01

Purchase the following parts: Two 9 volt snap in battery holders. One N-cell battery holder. One N-cell 12 volt battery.

Two 9 volt snap in battery holders. One N-cell battery holder. One N-cell 12 volt battery. www.mcmaster.com part number 7712K62. www.mcmaster.com part number 7712K91. www.mcmaster.com part number 7735K23.

02
Purchase the following parts: One roll stranded single conductor wire. One 6 length of continuous flex multi-conductor cable. One pair fully insulated alligator clips.

One roll stranded single conductor wire. One 6 length of continuous flex multi-conductor cable. One pair fully insulated alligator clips. Really any type of wire can be used to connect the alligator clips to the ignition controller as long as its capable of carrying enough amperage from the ignition controller to the rocket engine igniter. www.mcmaster.com part number 7587K325. www.mcmaster.com part number 7673K57. www.radioshack.com part number 270-354.

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03
Purchase the following part: 6 x 6 x 4 Plastic junction box.

6 x 6 x 4 Plastic junction box.

www.homedepot.com part number 499-979.

The plastic junction box will be used to house all the electronic components for the ignition controller. A foam seal between the box and the lid of the box keeps dirt and debris out.

04
Purchase the following parts: One liquid tight cord grip. One SPST heavy duty rocker switch.

One liquid tight cord grip. One single pole single throw heavy duty rocker switch.

www.mcmaster.com part number 69915K61. www.radioshack.com part number 275-690.

The liquid tight cord grip will keep dirt and debris out of the ignition controller as well as prevent the cord from being pulled out of the box.

MAKING THE IGNITION CONTROLLER

05

Purchase the following part: One wireless 2 channel momentary relay module.

One wireless 2 channel momentary relay module.

Search ebay.com for a wireless 2 channel momentary relay module. They usually cost between $20 to $30.

06
Remove the four screws holding the lid to the top of the junction box. Set the lid and screws aside for now.

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07
Using a 7/8 spade bit, drill a hole on the side of the junction box. Drill the hole on any side of the junction box about half way down the box and over to one side. See picture for clarification.

A spade bit is used for fast drilling of holes in wood and plastic. Spade bits have a forged, flat paddle with a guide point and cutting edges on either side.

08
Remove the plastic nut on the liquid tight cord grip and install it in the 7/8 hole on the side of the junction box. Tighten the platic nut to the back of the cord grip so that its secure.

The 6 wire that connects the ignition controller to the rocket engine will go through this cord grip.

MAKING THE IGNITION CONTROLLER

09

Using a 5/8 spade bit, drill a hole on the side of the junction box next to the cord grip. Drill the hole on the same side of the junction box as the cord grip, about half way down the side of the box.

A spade bit is used for fast drilling of holes in wood and plastic. Spade bits have a forged, flat paddle with a guide point and cutting edges on either side.

10
Remove the plastic nut from the back of the rocker switch. Put the switch in the 5/8 hole to make sure it fits correctly. Remove the switch and put it aside for now.

There are some wires that need to be soldered to the back of the switch before it can be installed on the side of the box.

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11
Remove the plastic insulating jackets from both alligator clips.

The plastic insulating jackets need to be removed so two wires can be soldered to the alligator clips.

12
Remove 6 of insulation from one end of the continuous flex cable.

MAKING THE IGNITION CONTROLLER

13

Cut wire number 3 and the green wire with the yellow stripe off at the base of the insulation.

Only two wires are needed to connect the ignition controller to the rocket engine igniter.

The wires in the continuous flex cable are marked 1, 2 and 3 along with a green wire with a yellow stripe.

14
Purchase the following part: Heat shrink tubing 1/8 to 1/16. Cut a 2 length of 1/8 heat shrink tubing. Install and shrink the tubing on the two remaining wires.

Heat shrink tubing 1/8 to 1/16.

Electrical tape can be used in place of heat shrink tubing.

www.mcmaster.com part number 7856K631.

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15
Purchase the following part: Heat shrink tubing 1/4 to 1/8. Cut a 2 length of 1/4 heat shrink tubing. Install and shrink the tubing over the cable insulation as well as the two wires.

Heat shrink tubing 1/4 to 1/8.

Electrical tape can be used in place of heat shrink tubing.

www.mcmaster.com part number 7496K435.

16
Strip 1/2 insulation from the end of each wire.

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MAKING THE IGNITION CONTROLLER

17

Put the two insulation jackets from the alligator clips on the two wires.

Once the alligator clips are soldered in place, it wont be possible to put the insulation jackets over them.

18
Solder the two alligator clips to the two wires.

Solder with rosin flux core.

Many articles and tutorials on basic soldering techniques are available online. Search Google, YouTube and Wikipedia.

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19
Slip the insulation jackets back on the alligator clips

The insulation covers on the alligator clips will prevent the two clips from touching and accidentally shorting the ignition controller.

20
Put two small pieces of 1/2 wide double stick tape on the back of each 9 volt battery holder.

3M Very high bond double sided tape 1/2 width or similar.

Silicone adhesive would be a good alternative to double sided tape.

www.mcmaster.com part number 75935A11.

12

MAKING THE IGNITION CONTROLLER

21

Cut a 2 length of 22 gauge stranded wire. Strip 1/2 insulation from both ends of the wire.

This wire will be used to connect a positive terminal on one 9 volt battery holder with a negative terminal on the other 9 volt battery holder. Putting the two batteries in series like this will produce 18 volts.

22
Solder one end of the wire to the negative terminal on one of the battery holders. Then the other end of the wire to the positive terminal on the other battery holder.

Solder with rosin flux core.

This wire will be used to connect a positive terminal on one 9 volt battery holder with a negative terminal on the other 9 volt battery holder. Putting the two batteries in series like this will produce 18 volts. Many articles and tutorials on basic soldering techniques are available online. Search Google, YouTube and Wikipedia.

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23
Put the free end of the continuous flex cable through the cord grip on the side of the junction box. Pull enough cord through so you have room to work.

Do not tighten the cord grip yet, that will be done in a later step.

24
Remove 6 of insulation from the end of the continuous flex cable. Cut wire number 3 and the green wire with the yellow stripe off at the base of the insulation.

Make sure you cut the same wires as you did in step #13.

Only two wires are needed to connect the ignition controller to the rocket engine igniter.

The wires in the continuous flex cable are marked 1, 2 and 3 along with a green wire with a yellow stripe.

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MAKING THE IGNITION CONTROLLER

25

Solder wire #1 to the remaining positive terminal on the 9 volt battery holders.

Solder with rosin flux core.

The wires in the continuous flex cable are marked 1, 2 and 3 along with a green wire with a yellow stripe.

Many articles and tutorials on basic soldering techniques are available online. Search Google, YouTube and Wikipedia.

26
Cut a 6 length of 22 gauge wire. Strip 1/2 insulation from both ends of the wire.

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27
Solder the 6 length of 22 gauge wire to the remaining negative terminal on the 9 volt battery holders.

Solder with rosin flux core.

Many articles and tutorials on basic soldering techniques are available online. Search Google, YouTube and Wikipedia.

28
Place the wireless relay module inside the junction box directly behind the cord whip.

The wireless relay module is held in place by two small sheet metal screws. Placing the module in the box will help to determine where the screws will go.

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MAKING THE IGNITION CONTROLLER

29

There are two holes on the relay module board for mounting screws. Using a black Sharpie marker, mark two spots on the junction box where the screws that will hold the relay module will go.

Black Sharpie marker or similar permanent marker.

30
Put the relay module aside and drill both holes in the junction box with a 1/16 drill bit.

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31
Using a small flat screwdriver, secure the wire from the negative terminal of the battery holder to the terminal block on the relay module marked NO1.

NO1 stands for normally open terminal #1.

32
Using a small flat screwdriver, secure the wire marked 2 from the continuous flex cable to the terminal block on the relay module marked COM.

COM stands for common.

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MAKING THE IGNITION CONTROLLER

33

Cut a 6 length of 22 gauge wire. Strip 1/2 insulation from both ends of the wire.

34
Solder the 6 length of 22 gauge wire to either terminal on the rocker switch.

Solder with rosin flux core.

This switch will power the relay module on and off.

Many articles and tutorials on basic soldering techniques are available online. Search Google, YouTube and Wikipedia.

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35
Put the 22 gauge wire and the rocker switch through the 5/8 hole on the side of the junction box. Attach the plastic nut that came with the rocker switch to the back of the switch. Tighten the lock-nut until the switch is securely in place.

This switch will power the relay module on and off.

36
Put a small pieces of 1/2 wide double stick tape on the back of the 12 volt battery holder.

3M Very high bond double sided tape 1/2 width or similar.

Silicone adhesive would be a good alternative to double sided tape.

www.mcmaster.com part number 75935A11.

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MAKING THE IGNITION CONTROLLER

37

Using a small flat screwdriver, secure the black wire on the 12 volt battery holder to the terminal block on the relay module marked GND.

This small 12 volt N cell battery will power up the relay module.

GND stands for ground.

38
Solder the red wire from the 12 volt battery holder to the remaining terminal on the back of the rocker switch.

Solder with rosin flux core.

This switch will power the relay module on and off.

Many articles and tutorials on basic soldering techniques are available online. Search Google, YouTube and Wikipedia.

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39
Using a small flat screwdriver, secure the 22 gauge wire from the rocker switch to the terminal block on the relay module marked VCC.

VCC stands for grounded voltage of the collector/emitter/base. For our purpose, it means the positive terminal of the 12 volt battery.

40
Carefully attach the relay module to the bottom of the junction box with two #6 x 3/8 Sheet metal screws.

#6 x 3/8 Sheet metal screws.

Silicone adhesive or double stick tape could be used in place of sheet metal screws.

www.mcmaster.com part number 90184A127.

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MAKING THE IGNITION CONTROLLER

41

Carefully push the antenna from the relay module through the cord whip so that its sticking out the end of the cord whip a few inches. Tighten the cord whip with an adjustable wrench until the flex cable and antenna are secure.

The cord whip will prevent the flex cable and antenna from being pulled out of the junction box.

The antenna on the relay module is a small black wire about 6 inches in length. The length of the antenna is critical to the proper operation of the relay module. Do NOT trim it or adjust it.

42
The components of the ignition controller and the wiring should now look like this.

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43
Install two 9 volt batteries and one 12 volt battery into the battery holders in the ignition controller.

Two 9 volt batteries. One 12 volt battery.

44
Hook up the two alligator clips from the ignition controller to the test probes on a digital multimeter.

A small light bulb can be used in place of the multimeter.

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MAKING THE IGNITION CONTROLLER

45

Turn the switch on the side of the ignitron controller to the on position.

The switch on the side of the ignitron controller isolates the relay module when the ignition controller is not in use. This extends the life of the 12 volt battery.

46
Press button A on the remote control and the multimeter should read 18 volts. Release button A on the remote control and the multimeter should read 0 volts. Put the cover on the top of the ignitron controller and secure it with the four screws that came with it. The ignition controller is now ready for use.

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