Custom switch-plate

The problem: 

8 zone Control4-based video and audio system at a Golf Club needs basic AV control in three rooms.  Must be able to turn TV on from the wall and select from three sources and change channel, must be reliable, must be simple to use and tamper-proof.  

I think I should explain the last point a little - We've installed a few Control 4 touch-screens in other areas at this project but only in the staff areas.  The new controls need to be located in rooms open to members of the public, and a drawback of using C4 touch-screens is that you cannot lock them down to only control certain areas, as far as I know.  We don't want AC/DC suddenly blasting out of the ceiling speakers in the Restaurant because a tipsy wedding party guest in the Function room is fiddling with the audio zone controls!

 

So, we came up with the idea of making a metal plate up, fitted with some momentary push-button switches.  
//Edit: I should add that each push-button would, when pushed, send a signal that the Control4 processor could react to.  Typically the programming would be something relatively simple like "When button 1 is pressed, Select Sky Sports 1 in the Members Lounge".


The cables in the back-boxes were terminated with RJ45's, so all we had to do was make the plates up, solder an RJ45 lead to the contacts, and plug in.  The other side of the cable is connected into a series of Control I/O Extender contact ports.

Shopping list:

1 x Aluminium plate - Designed by Samuel Howarth, machined by LS Fabrications - measured up to fit over a C4Infinity Edge back-box

6 x Push-button switches by Knitter, from RS Components

1 x RJ45 patch lead - stranded for better flexibility

1 x RJ45 coupler

First I made up the plate - the buttons were too big for the original holes so I had to drill them about 2mm wider - luckily it was Aluminium so soft as butter.

My work area consisted of a metal bits box with me sitting on the floor.  I was up against the clock so no time for luxuries.

After hunting around for a soldering iron (cheers Ash) it was time to tin up the end of the RJ45 patch lead. 

Then tin up both ends of some short 2.5" sections of stranded Cat5.  These will bridge all the common terminals of the switches.

Then label up the back of the plate, so it all makes sense when soldering each Cat5 colour to a switch terminal.  As you can see I didn't think of this until I'd started soldering.

Finished soldering.  Apologies for the photos btw, that'll be the iPhone 3g's fault.  I had to push the Cat5 flat when I brought it to the wall as the coupler got in the way - easier because it was stranded cable.

 We got the fabricators to make the mounting holes counter-sunk so the screws sat flat on the plate.

The finished plate.  I was quite happy with it, its quite utilitarian and as it's not labelled, a little bit mysterious.  Once the client knows what they want each button to do, we'll order some more and get them engraved by LS.

The programming was kept simple - 

Button 1 - Sky Sports 1

Button 2 - Central Blu-ray player

Button 3 - Local floorbox input 

Button 4 - Room Off

Button 5 - Sky channel up

Button 6 - Sky channel down

I'm going to add a bit more programming when we go back, but that should get the rooms up and running.  The clients staff all have iPhones with the C4 app running, and there are a few touchscreens dotted around for greater control. And yes, I know it's not straight!

It sits quite well on the wall for the first attempt.