Date: Tue, 4 Feb 2003 16:42:28 -0800
Subject: [weed] Home Made PTT thumb button HOWTO

I really like this PTT button because:
1) it looks like a "fire" button for my imaginary machine guns.
2) it is at the "tip" of the stick (thumb activated) so I do not
accidentally push it while I grip my stick in terror while in the pattern
when there is a strong cross-wind.  (no joke ;)

Anyway, here is how I did it:
Double check this, but I think you want a SPST N.O. Momentary Push Button
Switch.  I went to a local electronics store to pick one up so that I
could play with it first and make sure it was the size/shape/color I
wanted.

http://www.action-electronics.com/pdf/gcsw28.pdf  (see 35-410)

Could #51-244 work and cost only 25 cents?
http://www.hosfelt.com/en-us/dept_158.html

The key here is to make sure you pick one that is momentary - "Push ON"
and "Release OFF" (Not push on and then push again for off).

Next go through your junk drawer(s) and find an old _mono_ 1/8-inch
(3.5mm) headphone or microphone jack you can use.  (Or whatever fits the
PTT jack on your radio).  A the 1/8 in side of a cable like AC205 (bottom
right) http://www.recotonaccessories.com/products/audio/prod_audio.asp
would probably work good.

It does not matter which way you wire the switch - but I suggest plenty of
solder to make sure you have good strong connections.

I found a nylon washer that has the same outside diameter as the tube used
for my stick.  I drilled out the center hole of the washer to allow it to
slip over the switch.  I cut a small hole in the center of my hand-grip to
allow the button to pop through - but not large enough to allow the entire
washer through. My stick came from the factory with a plastic "plug" in
the end - I drilled a hole through the center for the wire to run through
(but it probably would have been fine to just discard that plug).

Then I assembled everything and used nylon zip-ties to route the wire to
my radio.

That's about it.  I suggest you test before you mount it.  ;)  It took me
about 15 min to get the (slightly undersized) hand grip to "slip" over the
end of the stick.  I had to use oil.  I am convinced that I will need to
_cut_ the hand grip off to remove it - so there is no chance I can take
pictures of the internals.