Using ExpressPCB for layout is convenient but they only have 1/2oz copper and use loose tolerances for their production service:
The edges of the board are cut with an accuracy of +/- 0.015″. A minimum of 0.020″ blank space is recommended between the perimeter and all features on the board. Traces placed closer than 0.015″ to the board’s edge may be routed off.
For the price & turnaround time, as well as based on past experience with them, this is an acceptable compromise.
Trying to cram the PCB into the Polycase TF-2409TX will be a tight fit, but I think I’ve got it.
Current Bill Of Materials form DigiKey:
| Index | Quantity | Image | Part Number | Description | Available Quantity | Backorder Quantity | Unit Price | Extended Price |
|---|---|---|---|---|---|---|---|---|
| 1 | 1050 |  | 565-4356-ND | CAP POLY 8400UF 35V T/H | 302 Immediate | 698 Lead Time | 2.75730 | $2,757.30 |
| 2 | 500 |  | 497-12305-ND | DIODE SCHOTTKY 60V 20A TO220AC | 500 Immediate | 0 | 0.71422 | $357.11 |
| 3 | 500 |  | 478-7802-1-ND | DIODE SCHOTTKY 40V 500MA 0805 | 500 Immediate | 0 | 0.14904 | $74.52 |
Also need to order:
- 12AWG wire (500′ of red and black)
- ground strap for the ground electrodes, and terminal rings
- split loom and heat shrink or tape
- 9005/9006/HID ballast power connectors – 200x
- potting epoxy
- enclosures