5. Assembling the Keypad & Control Board

The keypad, which is a replica of a TRW keypad, contains the control board, ESP32, lenses, enter button, volume knob, sd card slot and power supply. There are some important assembly steps that need to be followed for the keys of the number keypad to work properly with the 3d printed keypad housing and bezel.

The Number Keypad

What You'll Need:

1. Flush cutters OR a 2.5mm (3/32") drill bit and a drill
2. 3d printed keypad bezel
3. 3d printed keypad body
4. Number keypad
5. 4 small included screws

Disassembly

The number only keypad that comes with the TCD kit needs to be disassembled. Here is how:

1. Use flush cutters to cut the plastic welds off of the back of the number keypad OR use the 2.5mm drill bit to drill out the plastic welds - this method may be easier

2. Carefully separate the keypad pcb from the white plastic housing
3. Take out the rubber key membrane and keys
4. Put the keys in the 3d printed keypad bezel minus the # and * keys (make sure they are the correct direction and order!). If any of the keys are tight in the bezel, now is a good time to carefully trim any imperfections, from the hole where that key is held, with an x-acto knife.
5. Place the rubber key membrane over the back of the keys with the black pads up

6. Place the modified keypad assembly in from the front of the keypad body. This part will be easier if you hold the keypad with the key faces facing down.
7. Screw together the keypad pcb and the 3d printed bezel. Make sure the pcb is flush with the green keypad case. The cable connector on the pcb should be towards the bottom. _Tip: The screws may go in more easily if the screw holes in the bezel are drilled out with a 1.5mm drill bit. _

The Enter Button & Lenses (v1 & v2)

What You'll Need:

1. 5 colored led lenses
2. 3d printed button lens bracket
3. 3d printed enter button spacer
4. A small saw that can cut plastic

Cut the enter button

1. The enter button needs to be cut just below the threading to fit properly in the keypad body
2. Insert the enter button spacer into the lens when cutting is complete (this pushes the enter button on the control board pcb)

Put in the lenses

1. Take off the nuts from the led lenses
2. Insert the lenses into the lens bracket (red, yellow, green, white, white enter button) & screw on the nuts
3. Do not screw on a nut for the enter button

4. Carefully snap the lens bracket into the keypad housing. It will be a tight fit and trimming of the backet and/or housing may be required.

The Control Board

What You'll Need:

1. Control board
2. 4 included screws
3. 7p ribbon cable
4. Phillips screwdriver

Joining Control Board & Keypad

1. Connect the 7p ribbon cable from the control board to the keypad pcb
2. Carefully align the leds and enter button with the lenses already in the keypad

3. Make sure the control board sits flush with the mounting tabs of the keypad housing
4. Use your phillips screwdriver to secure the control board to they keypad using 4 provided screws