QRP Page 1 Kits and Construction A Report on a few available kits and one way to make PCBs at home...

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Kits and Construction

A Report on a few available kits and one way to make PCBs at home

Jim Larsen, AL7FS907-345-3190

[email protected]://www.AL7FS.us/

Ver 1.1 7/12/06By Jim Larsen, AL7FS

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Overview of Kits and Construction• What are some of the starter kits on the

market today (always changing)?• Kits – a sampler

– Small projects– Intermediate kits– Advanced kits

• Manhattan Construction• Making PCBs at home

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Why Kit Building?

• Adds depth to your ham radio experience.

• Sense of satisfaction at building it yourself.

• Can have functional test equipment at a fraction of the cost.

• Can Build your own station from kits.

• It’s FUN.

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Kitbuilding & Homebrewing

Given a chance, hams are natural builders and experimenters.

Thousands of schematics are available

Hundreds of kits and projects are

available today

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The “Tuna Tin 2 Transmitter” The “Tuna Tin 2 Transmitter”

• Simple Transmitter, less than 1WSimple Transmitter, less than 1W• W1FB original designW1FB original design• http://www.arrl.org/tis/info/pdf/7605014.pdfhttp://www.arrl.org/tis/info/pdf/7605014.pdf• Kit: http://www.megalink.net/~w1rex/QRPme/Kit: http://www.megalink.net/~w1rex/QRPme/

AL7FS to W1AW – 20 meters

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VE3DNL Marker Generator

• “Markers” that we can hear in a receiver

• Outputs are are 5, 10, 20 and 40 kHz.

• Outstanding instruction manual with many photos.

• $7.50 shipped in the US

•http://www.norcalqrp.org

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““Herring Aid” Receiver Herring Aid” Receiver

• Simple Receiver project - July 1976 issue of QST Simple Receiver project - July 1976 issue of QST • Mate to Tuna Tin 2 transmitterMate to Tuna Tin 2 transmitter• http://www.njqrp.org/tuna/herring_text.htmlhttp://www.njqrp.org/tuna/herring_text.html NorCal Herring Aid 5 – Updated versionNorCal Herring Aid 5 – Updated version

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SMT QRP Dummy Load • Learn working with surface mount parts

• Uses 44 2.2K resistors in parallel to result in a 50 Ohm load.

• Put it together in an hour

• Pwr Handling 10W for 1 min. 5W for 3 min.

• US orders: $7.50

• http://www.norcalqrp.org

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NorCal Keyer• Memory keyer

• 3 programmable 40-character memories

• Iambic A & B mode, straight key and bug mode

• 2 beacon modes, and variable speed control by either a 100K pot or the paddles themselves.

• How to: http://www.norcalqrp.org/nckeyerelmer.htm Covers every detail of kit. by Jim Kortge, K8IQY

• US orders: $16.50

• http://www.norcalqrp.org

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NorTex QRP Club Accuprobe

• Measure RMS voltage in your transmitter so you can measure power out.

• More sensitive than old .01uF, diode RF probes.

• US Price: $ 17.00 • http://www.kk5na.com/kk5na_files/accuprobe.htm

• Use with NoCal SMT Dummy Load• useful for measuring RF signals with predictable results from 100 kHz to at least 30 MHz at levels ranging from 10’s of millivolts up to 35 V rms.

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4SQRP Tenna Dipper

• http://4sqrp.com/kits/td/td.htm

• US $25

• 4SQRP = Four State QRP Club - Arkansas, Oklahoma, Kansas and Missouri

• Gives you an indication with an LED of when your antenna tuner is looking at a 50 ohm load

• Great for in the Field

• Quickly adjust tuner

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The “Pixie” The “Pixie”

• Simple 250mW transceiver kit from HSC ElectronicsSimple 250mW transceiver kit from HSC Electronics

Bruce Hopkins - KL7H built his for 3.920 and 3.933. Checkins were successful with net control on both Motley and Snipers Nets

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The N0SS HF Noise SourceThe N0SS HF Noise Source

• Noise Source KitNoise Source Kit• Easy to build w/o kitEasy to build w/o kit• Spectrogram Spectrogram softwaresoftware• Easy readout – filtersEasy readout – filters• This is 150 Hz BW on K2This is 150 Hz BW on K2• Make your own PCBMake your own PCB

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A Simple and Inexpensive A Simple and Inexpensive Morse Frequency Display Morse Frequency Display

• Small Wonder Labs’ “Freq Mite” $20Small Wonder Labs’ “Freq Mite” $20• PIC microcontroller as digital frequency meterPIC microcontroller as digital frequency meter• Speed of readout on the FREQ-Mite is 13 WPMSpeed of readout on the FREQ-Mite is 13 WPM•http://www.smallwonderlabs.com/ http://www.smallwonderlabs.com/

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Small Wonder Labs’ SW40+” Small Wonder Labs’ SW40+”

• 40m 2W CW transceiver – 20 meter version for AK40m 2W CW transceiver – 20 meter version for AK• Improved, simplified – provide your own caseImproved, simplified – provide your own case• RIT add-on possibleRIT add-on possible• Educational ProjectEducational Project• http://www.smallwonderlabs.com/ http://www.smallwonderlabs.com/ $55 (postpaid) to US$55 (postpaid) to US

Elmer 101 http://www.qsl.net/kf4trd/faq.html

AL7FSAL7FS

• Built by AL7FSBuilt by AL7FS

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The NorCal 40A - Transceiver The NorCal 40A - Transceiver

• 40m 2W CW transceiver40m 2W CW transceiver• Grandfather deluxeGrandfather deluxe• Still availableStill available

• http://www.fix.net/~jparker/wild.htmlhttp://www.fix.net/~jparker/wild.html Wilderness RadioWilderness Radio

• The new Wilderness NorCal 40A is $139 The new Wilderness NorCal 40A is $139 plus shipping ($6 U.S.) plus shipping ($6 U.S.)

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The NorCal 20 TransceiverThe NorCal 20 Transceiver• 20m superhet CW• Great front end• NorCal kit for 3rd world countries• No Longer Available• Available used

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The “Sierra” The “Sierra” by Wilderness Radio by Wilderness Radio

• All band CW transceiverAll band CW transceiver• Superhet, VFOSuperhet, VFO• Digital display & key are optionsDigital display & key are options• Removable band modulesRemovable band modules• Rivals quality of rigs 5 times the costRivals quality of rigs 5 times the cost• http://www.fix.net/~jparker/wild.htmlhttp://www.fix.net/~jparker/wild.html• basic Sierra kit is $215, plus shipping ($8 U.S) basic Sierra kit is $215, plus shipping ($8 U.S) • Fully loaded is $369 with all 6 band modules Fully loaded is $369 with all 6 band modules

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OHR – Oak Hills Research OHR – Oak Hills Research

• Single band superhet CW rig• + improved• Price is now $139.95• http://www.ohr.com

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OHR – Oak Hills Research OHR – Oak Hills Research

• 5 band superhet CW rig5 band superhet CW rig• 5 band + improved5 band + improved• $359.95$359.95• http://www.ohr.comhttp://www.ohr.com

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Elecraft K1 transceiverElecraft K1 transceiver

• http://www.elecraft.com

A compact, high-performance CW rig that you can build. A compact, high-performance CW rig that you can build.

five watts is all you need to work worldwide DXfive watts is all you need to work worldwide DX

four bands into the affordable, easy-to-build K1-4 transceiverfour bands into the affordable, easy-to-build K1-4 transceiver

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John Hendricks – AL7OKBird Point, Alaska with Elecraft K1 Transceiver (kit)

2002

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Elecraft K2 transceiverElecraft K2 transceiver

• http://www.elecraft.com

• The K2 is a full-featured HF transceiver• Build the K2 for QRP or 100W Operation • Can challenge even the Yaesu FT1000 Mark V on Rx• And you build it yourself…just like the old Heathkits

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Elecraft K2 - AL7FSElecraft K2 - AL7FS

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Elecraft KX1 Portable

• ultra-light, multi-band CW station with internal battery and automatic antenna tuner, full 20 and 40 meter ham bands, with 30/80 meters optional.

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Manhattan Construction

Pads avail. Pads avail. From FAR From FAR CircuitsCircuits

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Manhattan Construction

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Manhatten – My Dead EndDead End…for now.

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PCBs via Toner Transfer (TT) Why build my own boards?

Seemed like fun. Cost can be low. For over 40 years Boards stopped me. Manhatten Style is cool but I never seem to get started. Front-end load the hard work and finish with fun.

So What is Toner Transfer Method??

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Lets build a simple circuit:•Zapper circuit schematic.

• From Dr. Clark's book "The Cure For All Diseases“

•Only the schematic is provided from web source

• What to do……??

•http://www.members.aol.com/mas1911/index.html

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Dip Trace – Draw the Schematichttp://www.diptrace.com/http://www.diptrace.com/

Diptrace has a Free Version: Freeware edition does not support Diptrace has a Free Version: Freeware edition does not support export to DXF, Gerber and N/C Drill, max. number of pins — 250.export to DXF, Gerber and N/C Drill, max. number of pins — 250.

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Zapper Schematic

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Diptrace Convert to PCB –Step 1

Next Step is to move the components Next Step is to move the components to the layout you would like.to the layout you would like.

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Run AutoRouter

Scale 400%Scale 400%

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Print to Transfer Paper

• Tried Inkjet Photo Paper with zero successTried Inkjet Photo Paper with zero success• Plain Costco bulk white paper workedPlain Costco bulk white paper worked

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Clean PCB Board

• Tarn-X First• Board was old with fingerprints

• Dishsoap and hot water• Scrub down with rough green scrub pad from Carrs

• Don’t touch surface from here to the end

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Transfer Toner to Board

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Remove Paper from Toner

Soak 20+ Min. Warm, Soapy Water

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Rub off the Paper

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Rub off the paper

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Circuit Ready for Etching

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Choices at This Point• Etch all Four circuitsEtch all Four circuits

• Need to touch up traces and PadsNeed to touch up traces and Pads

• Cut the best board free of othersCut the best board free of others• Needs No touchupNeeds No touchup – – 3 good3 good 1 bad 1 bad• Uses less tonerUses less toner• Find a shear for cleanest cutsFind a shear for cleanest cuts

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Etching the Board

• I used old Etching Solution – 15 years old (Not a good idea)

• Temperature of solution was only about 68 degrees (Not warm enough)

• Bottle says up to two hours

• I took 65 minutes – That’s too long

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Etching the Board

• Used a throw-away brush to gently wipe the surface and keep fresh solution on the copper

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Etching the Board

• Copper slowly is eaten away • Only the circuit will remain

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Etching the Board

• The Etching is complete • Some circuits are good, others not good

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Etching the Board

• This one looks pretty good but with some pitting

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Cleaning off the Toner

• Acetone was used to clean off the Toner from the circuit pattern•Left black smudges on the board – No answer for this yet

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Cleaning up the Traces

• My etch process undercut the toner in places• I inspected each circuit with a magnifying glass• In places I added a jumper to assure continuity

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Cleaning up the TracesSolder Paste rubbed on Solder Paste rubbed on circuitcircuit

Temp. – 750 F

Solder Wick = solder Solder Wick = solder brushbrush

Paint the traces with Paint the traces with SolderSolder

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Cleaning up the Traces

• Solder on traces protects the copper from corrosion•Better products to use, e.g. TINIT tinning powder

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Additional Cleanup

• Poor traces repaired with small wire and soldered into place

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Finishing touches• Small drill press is a requirement•Small diameter drill bits need drill press• Drill bits need to be carbide tip drills• Don’t breath the dust from drilling

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Final Touches

•Use toner transfer method again to add Use toner transfer method again to add component outlines on the topcomponent outlines on the top of the of the board. Can useboard. Can use household ironhousehold iron or or laminator to fix the tonerlaminator to fix the toner• Solder in the components Solder in the components • Test the circuitTest the circuit• Install in a chassis as desiredInstall in a chassis as desired

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Component Outlines

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Finished Board w/Parts

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Final Comments• This is my This is my firstfirst attempt at toner transfer. attempt at toner transfer. • I offer my observations as a learning toolI offer my observations as a learning tool• I plan to keep trying new techniquesI plan to keep trying new techniques• There are There are Many variationsMany variations on this on this techniquetechnique• Board cleaning methods used by me not Board cleaning methods used by me not best. (e.g., the acetone black smears)best. (e.g., the acetone black smears)• My etching technique undercut some traces My etching technique undercut some traces (Needs major improvement)(Needs major improvement)• Great potential with this techniqueGreat potential with this technique

Give it a try Yourself !!Give it a try Yourself !!

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Links for Toner Transfer

• http://www.diptrace.com/ HomePage for DipTrace software

• http://groups.yahoo.com/group/diptr/ Mail List for DipTrace

• http://groups.yahoo.com/group/Homebrew_PCBs Mail List for homebrew PCBs

• http://max8888.orcon.net.nz/pcbs.htm another step by step example

• http://www.Google.com/ search on “toner transfer method”

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Alaska QRP Club

• No officers, no directors, no constitution & No dues.• Meets the Third Friday of every month - 7:00 PM (Some show for dinner at 6PM)• Meet at Dennys (in the back room) on DeBarr near Bragaw. • Contact is Jim Larsen, AL7FS, 345-3190.

[email protected]• http://www.qsl.net/kl7aqc/

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Questions?

Download presentation at:Download presentation at:

http://www.AL7FS.us/http://www.AL7FS.us/

QRP Page 1 Kits and Construction A Report on a few available kits and one way to make PCBs at home...

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