Building Ronja Starquake airwire

We are going to build Starquake electronics.

Soldering bottom lid

Solder bottom lid to the body from inner side only using soldering iron, solder and rosin flux.

Contact flaps

Cut brim of the (unsoldered, top) lid once on the short side and twice on the long and shape the flaps so all of them have reliable contact with the box.

There are two possibilities how to drill out the box. First one is using a calibrated printer, printing out a template and gluing the template on a tin. The second one is measuring everything by hand.

Postscript / PDF / EPS / BIG png / DXF (qcad)

Option 1: Drilling template

Print out this template and glue on the tin box.

Postscript / PDF / EPS / BIG png / DXF (qcad)

Option 1: Drilling

Drill out holes on the template. Use the wire nut as template for it's mounting holes. During drilling use the M3 bolts and possibly also nuts to hold down the nut in already drilled holes. After drilling, soak the template off in water and throw away.

Postscript / PDF / EPS / BIG png / DXF (qcad)

Option 2: making the box with manual measurements

Make the box according to the plan. Use hard stylus or thin marker for nonporous surfaces for drawing lines. Use square for maintaining perpendicularity and centre punch for making centres of holes.

Grommets

Install two 4mm grommets into two of three 6mm holes according to the photos.

Postscript / PDF / EPS / BIG png / SVG (Inkscape)

Making L stubs

Make 2 L-Stubs according to the picture. Cut also 2 20mm long straight bare pieces from the same wire.

Installing wire stubs

Install 2 insulated L-shaped wire stubs into the grommets. Prepare straight uninsulated wire stubs.

Mounting wire nut

Wrench is 5.5mm. Use 3 M3x15 bolts and 3 M3 washers and 3 M3 nuts and tighten. Install ends of L stubs into the wire nut and tighten. Insert and tighten the two 20mm long uninsulated straight wire stubs into the remaining slots of the wire nut on the same side as the previously installed L-stubs.

Soldering down straight stubs

Solder down the straight wires onto the tin box.

Postscript / PDF / EPS / BIG png / SVG (Inkscape)

Color bands

Apply color bands with shown colors made from duct tape. Remember this drawing for future reference when soldering the circuit inside.

LED

Insert LED (D102) into the remaining hole in the box. Glue it down using thermal glue pistol.

We are going to solder an airwire construction. The IC will be glued down on it's back. The interconnections will be soldered using a hard wire, solder and rosin flux. A transformer soldering iron (the one with the loop) or regulated-temperature iron is used for this.

Write on chip's bottom side it's designation again (use paper stickers). Glue chip down on it's backs somewhere in the middle of the box.

		PostScript	PostScript + Gzip	PDF
Color	Dark	starquake_01.ps	starquake_01.ps.gz	starquake_01.pdf
	Light	starquake_00.ps	starquake_00.ps.gz	starquake_00.pdf
	Small	starquake_02.ps	starquake_02.ps.gz	starquake_02.pdf
B/W	Dark	starquake_11.ps	starquake_11.ps.gz	starquake_11.pdf
	Light	starquake_10.ps	starquake_10.ps.gz	starquake_10.pdf
	Small	starquake_12.ps	starquake_12.ps.gz	starquake_12.pdf

starquake.sch (gschem)

Component lists

Seznamy součástek

Soldering

Solder in all the parts according to the schematic in this order:

U101
IC blocking capacitors: C101, C102, C103
The rest

Correctness check

Take the Starquake and inspect it completely.

Left-out components
Left-out wires
Wires leading somewhere else than they should lead
Correct values of passive components
Correct IC type
Correct orientation of IC
Correct orientation of diodes.
Correct orientation of polarized capacitor

Postscript / PDF / EPS / BIG png / SVG (Inkscape)

Labels

Print out the Starquake labels. Stick the large label on the outer side of the lid and fill in. Stick the small label on top of the box (where wire nuts and switches are).

Print out the small schematic (see the Soldering section above) and glue on the inner side of the lid. Cross over any component that is replaced by an equivalent and inscribe the true equivalent type.