Homemade audio control

Rhino

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I'm toying with the idea of a DIY solution that provides some audio panel capability with two radios, without having to buy an audio panel. It can't be done without buying some hardware and engaging in some very involved wiring, but I think it can be done in a workable and relatively inexpensive way. I'll preface this by saying I don't know if this is a good idea, or whether or not it will work. I also have no way to test it. But I've been getting a lot of queries concerning the feasibility of something like this, so I decided to play around.

Below is a first draft of my idea. It uses three readily available switches, two relays, and two AMX-2A mixers from VX Aviation. Not being an engineer, I've probably complicated it needlessly, but I'm hoping some of our engineering types can point out what I got wrong (and I'm sure I got some things wrong).

IMAGE DELETED. SEE MOST RECENT DRAFT BELOW.

This setup removes the volume control capability from the SV-INTERCOM-2S, so it's all or nothing. In fact. it bypasses the intercom almost entirely, and could be made to replace it completely with a bit more work. You could add some rheostats for volume control if you wanted. I didn't add a whole lot extra, because it eventually gets to the point that you may as well just get the audio panel. In fact, I may revamp it at some point to eliminate the intercom entirely.

There's somewhat less than $400 of equipment to purchase here, and a lot more work.

This configuration allows each pilot to choose what they listen to, Com 1, Com 2, or both. That's why it requires two mixers, and bypasses most of the intercom. The intercom mixes, but it doesn't give the ability to only listen to specific radios.

There is a com 1/com 2 selector switch for PTT, but it affects both pilots simultaneously. They will both transmit on whichever radio is selected.

This configuration is mono only. Unless you have twin engines or dual EMS modules, you aren't using stereo anyway.

I haven't gotten to designing it yet, but music can be added, either through the intercom or directly from the mixers. Again, it will be mono only though. You can get stereo mixers, but they cost more, and this is intended as a poor man's alternative to an audio panel.

Anyway, feedback is appreciated.
 
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Rhino

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Wow. 45 views and no comments. Not very likely I got everything right on the first try, so I'm guessing maybe I just made it too complicated to motivate anyone to examine it closely.
 

Rhino

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The AP-60 mixer from Flight Data Systems is $89. That gets the hardware cost down to just a bit over $200, but the pinout would be a bit different than what's pictured above
 

Rhino

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Draft 2 adds individual 2K potentiometer volume controls for Com 1 and Com 2. This replaces the single volume control on the intercom that controls both radios together.

IMAGE DELETED. SEE MOST RECENT DRAFT BELOW.

This gives you a total of three new switches and two knobs on your panel.
 
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Rhino

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I should note that the above configurations will not automatically mute music when a radio transmission or alert audio from the Skyview is received. The next draft will try to restore that feature, and will use the less expensive AP-60 mixer. Stay tuned.

I will also note that, although I don't actually depict shielded cables to the resistors, switches and relays, it most definitely should be used. ALL cables that route audio should be shielded, and that shielding should be grounded at the SV-INTERCOM-2A.
 

Rhino

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Draft 3 adds the automatic muting function from the intercom back in. It also simplifies the diagram by eliminating some of the criss-crossing. Unfortunately that made it a bit bigger.

IMAGE DELETED. SEE MOST RECENT DRAFT BELOW.
 
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Tim Fitz

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You're not on your own Rhino, it's just a lot of work to review. Makes my head hurt just looking at all you have done. Having just redone my panel I am not ready for another melt down of my brain. What are you putting this in?
 

Rhino

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I'm not right now. I've just had several people ask if it could be done, and how.
 

Rhino

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Forgot to mention, draft 3 also has the music input to the intercom, which is what the muting function is for.

I also did not add the AP-60 mixers yet. Not sure if anyone's interested.
 

Rhino

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And I suppose I should address features, since that's what folks asked for.

What this setup gives you:
  • Individual volume controls for each radio rather than one control for both.
  • Ability for each pilot to select audio from Com 1, Com 2, or both.
  • Switch to select which radio gets PTT.
What you lose:
  • Ability to control master volume of both radios with one knob on SV-INTERCOM-2S.
 
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Rhino

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Paint. I have a better program somewhere, but it's easier just to copy and paste stuff from previous versions made in Paint.
 

Rhino

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Draft 4 simplifies the diagram by removing the music and microphone jacks, since they still install as depicted in the Dynon installation manual. Then I 'un-simplified' it by adding in shields.

1676679774943.png
 
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