Next is the main circuit board for the Speedmachine electrical system. Photos are here http://img105.exs.cx/gal.php?g=dscn0002dce6zf.jpg

The first photo shows the cleaned and prepped copper clad circuit board before etching. Photo 2 shows the board in the etching tank. The ferric chloride solution is about 120° and the bubbles are from the air agitator. I takes about 20 minutes to etch a board, and then you rinse it off, remove the resist with solvent, and drill the holes for the wires and mountings. Then you mount the parts, starting with the smallest, and solder and trim the leads. Photo 3 shows the completed main board populated with components.

To help the board withstand vibration, all the components are mounted flush to the board. two leftmost capacitors and the six small plastic transistors will be glued to the board with a dab of RTV once testing is complete. Another option would be to pot (embed) the board in epoxy, but that would make it impossible to repair and would add weight.

The power supply board is next. The purpose of this board is to mount the three 7812 voltage regulators and provide connection points to them. The photo shows the completed board with the regulators mounted. This board will also be inside the main module, which will be mounted to the back of the seat with a 3" x 5" aluminum bracket. The voltage regulators get hot and need a heat sink, and that aluminum bracket is a perfect heat sink, so I cut 3 large holes in the front of the module enclosure where the aluminum bracket will attach. I will bolt the voltage regulators to the aluminum through the holes. The last picture shows the main module with 3 holes and the tail light on top.