1982 Sega Star Trek Captains' Chair Restoration

The last week or so; I've been working on a new method to edge lite the Etch.
About two months ago; I did a 6in scale test of a peice of clear bonded to the smoke grey acrylic and lit by some white LEDs.



The scale test was awesome enough to warrent a full scale build with some super bright red LEDs. It was at this point I realized I wanted the etch to be lit during game (red) and when the game was idle (white). So I went ahead and redesigned the Red Alert Audio PCB to "invert" the red alert for when the game isn't in progress. As I began simulating the "invert" circuit in LTSpice; I decided it'd be cool to also have a "Bass response" so that when the ship was hit by enemies; or fired upon, there'd be a suttle "Flash" during the game play.

From these ideas the Star Trek Ambient Lighting System was born:

However, please note that the above circuit is non-functional as a couple of bugs were found in the current mirrors which will require a respin of the circuit and PCB.

U1 / U2 / D3 R3/R2/C1/M3 is basically the same from the previous circuit. It detects the game audio and turns on the Red LEDs. Q1/2/4/50/51 make up a basically broken current mirror which is suppose to output 18mA (for normal LEDs) and 50mA for the high current LEDs I'm going to use for the edge lite acrylic. I had simulated the current mirror and in the computer; it gave me the 18mA results - but when I acutally built the PCB - I never got even close to the desired currents.

U2B and it's circuitry; become the "white LED" inverter circuit. When Red isn't on; the White LEDs come on after ~0.33 seconds.

U2D makes up a BASS pass filter with 2V/V amplification and a pole frequency of ~200Hz. When "explosions" or low frequency signals come in from the audio amp; the signals are sent to the U2C comparitor where is is passed to the peak detector of R23/C8. The effect has a decay of 1/3 of a second; so the BASS LEDs will only fire briefly after the audio goes away. The Current mirros of Q8/Q52 is broken but is suppose to to deliever 50mA to the high brightness Yellow LEDs.

U2A also drives the gate of M1 which controls SPDT relay K1. This relay is an aux port intended to allow one to drive external devices such as a CCFL for the Canopy ( :) ). Common J3-2 is switched between J3-1 (in game) and J3-3 (not InGame). JP1 is a solder bridge to enable 12V from J2 to tied into J3-2 (common).

More complex? Yes. But also should give us a nice effect. I assembled the board; debugged it and did some rework on the back side of the board to fix these bugs. Here it is mounted:


And a Close up:

I haven't put the AUX port to use (blue three screw terminal connector). J2 is the bigish 2x5 right angle connector at the top. This supplies power input (12VDC) and current outputs to the LEDs.

Functionally; the circuit draws (with LEDs connected):
100mA with White (idle / not inGame)
300mA with Red (in game, no explosions)
410mA with Red+Yellow (ingame, explosions)
 
Now that I had a working circuit board; It was time to turn my attention to HOW I was going to make the Edge Lit peice. In the scale; I used a zip-lock bag and vacumm clamped the smoke grey and clear peices together. I need to ramp this up to full scale. So I cut a peice of scrap wood into a 22x11.5 section. This would become the back peice to the vacumm clamp. I covered the wood in two layers of plastic window screen (net) so that the air could be evacuated from around the read window. This was placed inside a LARGE ziplock(tm) storage bag (2ft x 1.7ft size). and a hole was drilled thru the plastic and wood to create a vacumm port. Finally Foam Weather stripping was placed on the bottom of the back around the vacumm port to create a seal.

My local plastic company only carries the smoke acrylic in 1/8" as its smallest thickness. I was hoping for 1/16" so I could put the clear peice as 1/8" and the smoke as 1/16: - but since they didn't carry the smaller thickness; I had to invert the ratio.

I used liquid acrylic cement to fully cover both the clear and smoke peices. This part is hard because the cement evaporates quickly. Also if you peice near spotlessly clean; you get little peices of acrylic shavings from the raw cut between the two peice. Anyway; with the pieces wet with cement; they are placed together and put in the ziplock bag with a peice of the window screen on top. The inital vacumm is pulled with the shop vac, then the secondary vacumm pump /chamber is applied with the ball valve. This brings the two peices under 15lbs/sq inch of pressure; squeesing the two peices together and removing most of the air bubbles.


Here's the peice under clamp:


And a closeup:


I clamped it for a couple of minutes; just long enough for the acrylic cement to begin bonding the two peices together.

I waited about an hour; then laser etched the window design into the clear side.

The peice wasn't perfect. There was some foriegn material and airbubbles in the final peice.

Some learnings from this:
1) The cement evaporites/dries quickly. There must be a better way to apply it - in a thick enough application to help mininimize the air bubbles.
2) Peices need to be clean and done in a clean eviornment. Ideally done is a "cleanroom" hood. I got small peice of acrylic between the two sheets and it cause a pressure point that got a star-like facture pattern.
3) not enough cement; and the peices get weird optical patterns between them.

The bubbles aren't real bad; and the fracture pattern adds some character to the peice; so for now - I keep it.
 
I knew I DID NOT want to try and solder 20 or so LEDs manually to the edge of the new peice. Also; I was going to use some high power Red and Yellow LEDS which require 50mA of current. As a result they recommend that the PCB they are mounted to have a certain sq area of copper to dissappate the heat from the LED. These two forced me to create a 21inch x ~0.19 inch circuit board to which I'd mount a series of LEDs.
10 qty Red 50mA LEDs
6 qty White 18mA LEDs
4 qty Yellow 50mA LEDs

The 10 reds were driven by maximum number I could string together for a 12V source. 6 White; same ... smaller number because the Vf of the white LEDs is almost double the Vf of the red. The Yellows were limited by PCB realestate... Those Red LEDs require quite a big "heat sink" on the PCB; so there was only enough room for four LEDs.

The other limitations; are that most PCB panels are around 10" in their largest dimesion. So; I couldn't exactly have a 21" PCB made. Further; My hobby use PCB system only allows for at most 5 or so inches before you hit their hobby "limiter". As a result I had to break up the PCB into four sections so I could lay it out:


These four sections would be soldered together to create the 21inch length. Each PCB section is joined with the next via a 3x2 pad configuration. This turned out to be a real PIA to solder because I had to make the pads so small and close together to make 6 signals fit on two sides. I need to tinker with the connection pads to make them more hand solder friendly.

I started by super glueing the sections together - then soldering the wires in place and finally; covering with 5minute epoxy. Even in this configuration; the PCB is very fragile until it's mounted to the edge of the acrylic sandwhich. Speaking of which:

It is epoxied to the edge of the acrylic. The Red rework wire is necessary to connect the L and R yellow diodes together in series.

On the connection side to the main PCB; I soldered 6 wires from a ribbon cable to the SMT LED PCB. I tell you; that was a real PIA. Then glued the LED PCB to the acrylic. This ribbon cable connects to J2 on the main PCB.


There was a bit of light leakage from the sides where the LEDs are; so I cut some aluminum foil and glued it shiny side down on the top and bottom.


Then covered with clear packing tape to help prevent tearing during install into the corner peice:


I then had the carefully manhandle the much thicker Acrylic+PCB into my corner peice and reassemble the back corner.
 
I put the machine together - I kept the red light bar... and added the ambient light edge. Here's some final pictures:

These had to be taken with long exposure times (30seconds) with no flash to get a more accurate representation of what the etches look like.

Game Idle:


InGame:



A exposure with all the colors which I thought looked cool:


And A video for your gawking pleasure:


For now; I consider the back canopy window complete... the edge lit etch looks pretty darn good... If I do something further; it'll proably be after I complete the mutitude of other projects I have in the queue.

Whatcha think?
 
Ok.. Andrew over at the VectorLists came up with this idea of using a laser projector to "play" our favorite vector games on a wall , ceiling, ect.

I think it's an awesome idea; and, I've come up with some initial brainfarts based upon some quick google searches:

First; It appears that an iLDA compatible laser projector might fit this project exactly:
http://www.laserist.org/StandardsDocs/ISP05-finaldraft.pdf
see pp8

says X,Y is +/-10
RGB is 0-5V
These almost match the output of my sega g08.

The only "problem" is to convert the output of the vector generator into a differential signal. Probably a "simple" differential opamp would foot the bill.

China seems to have a inexpensive RGB iLDA projector.My concern of course is it's china merchandise. Unsure of the quality, MTBF, etc.

Anyone know of a better deal / manufacturer?

I *SO* want to embark on this project; just wish I had the time.
May find the time... need some encouragement. :p

Comments / suggestions?
 
No.
The Laser projectors are already "vector" machines. They take analog "points" to plot the image.
VectorVGA converts vector to Raster; which isn't what we want.

I think all we need is a "signal conditioner" which takes the Vector outputs of the vector arcade and output +/-10V into the iLDA port of the laser projector.
 
everyone must be busy getting ready for the holidays.

So ... happy holidays to all the followers of this restoration. ;)
 
Ok.. Andrew over at the VectorLists came up with this idea of using a laser projector to "play" our favorite vector games on a wall , ceiling, ect.

I think it's an awesome idea; and, I've come up with some initial brainfarts based upon some quick google searches:

First; It appears that an iLDA compatible laser projector might fit this project exactly:
http://www.laserist.org/StandardsDocs/ISP05-finaldraft.pdf
see pp8

says X,Y is +/-10
RGB is 0-5V
These almost match the output of my sega g08.

The only "problem" is to convert the output of the vector generator into a differential signal. Probably a "simple" differential opamp would foot the bill.

China seems to have a inexpensive RGB iLDA projector.My concern of course is it's china merchandise. Unsure of the quality, MTBF, etc.

Anyone know of a better deal / manufacturer?

I *SO* want to embark on this project; just wish I had the time.
May find the time... need some encouragement. :p

Comments / suggestions?

Great idea!
 
Holy Crap.....

I just burned about 1 hour at work reading this thread from the beginning. Funny thing is I kept looking at the posting dates as I went along, hoping you would have it complete by the time I reached the end. No such luck... now I have to follow along with everyone else.

After reading the whole thread I think it would be cool if you could create a post with numerous cab and gameplay pics in the same post. I know you aren't quite finished yet, but a general overview of your progress to date would be great. I am afraid this thread is going to turn into a Robert Jordan novel and I will have to fish back to old posts to see the bits and pieces that are completed so I can remember what has been done so far.

Other than that.... you need to see if there are any comic book conventions near you and get that damn thing autographed! In the last 3 years we have had Shatner, Nimoy, and Takei here in Seattle. There has got to be a way......

Keep up the good work. This project has put you into the pantheon of restoration/modification Gods. All hail Zitt!!!
 
Other than that.... you need to see if there are any comic book conventions near you and get that damn thing autographed! In the last 3 years we have had Shatner, Nimoy, and Takei here in Seattle. There has got to be a way......

Keep up the good work. This project has put you into the pantheon of restoration/modification Gods. All hail Zitt!!!

Thanks.
I have my Star Trek: 25th pinball signed by all living actors
and my STNG Pinball is missing Geordi and Crusher.

Working on a FreePlay mod for the Chair at the moment.
And the Vector monitor calibrator tool.
 
I went ahead and built a 555timer circuit which works to provide free credits on my Sega Star Trek Captain's Chair. I haven't yet tested it on my other machines; but plan to test it on my Bally Star Trek when I get them back from BatchPCB.

The 555 Timer circuit and PCB licensed under TAPR/NCL Open Hardware License. Simple thru Hole componets should allow most people to solder this project over a evening. Timer circuit used to stimulate the coin circuits of a Sega Star Trek Captain's Chair to enable "Free Play" - IE use the game without quarters. This circuit should be flexible enough to work on most arcade games. This circuit can be built for less than $23.
http://Pinball-Mods.com/blogs/?p=155

 
My captains chair has a push button installed to add credits. I'm not sure why you say on the linked site that it wouldn't work. I mean cool job designing free play the circuit.
 
My arcade was a little too... bare!

The Answer? Some Custom Star Trek Neon from our friend Gu:










Anyone who 'as played the game will understand the first two. ;)
 
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