Installing the various components to get the HT controller to work was probably my favorite part of the build. Something satisfying about seeing everything coming together. At a high level these are the key components:
Arduino : Brains of the operation
Custom circuit board : Connections out from arduino and 5v power regulation
Relays : control each of the 2 outlets (cable modem and router)
Scavanged switching power supply : 120v ac to 12v dc
DB9 : connection out to the power strip where a relay controls each of 6 outlets/amps
So everything was installed on nylon spacers, with small machine bolts coming up through the bottom. That can be seen well on the relay installation:
And here is the custom circuit board I created in my isolation routing tutorial. All wired up to the front panel, buttons, db9, and relays:
Overall unit in early assembly:
And (almost) final:
Primary lesson learned on this assembly was when routing a circuit board that you are going to attach ribbon cables to, ensure the holes are lined up straight. Do not stagger them as I did, it makes it very difficult.
I also learned that when soldering to plain copper boards you really need Flux – more than than what is in your solder. I had good luck with some acid-based plumbers flux I had laying around. I put that on the board where the pads where, and then tinned them. Don’t forget to clean it of with rubbing alchohol or acetone.