Ronja Twibright Labs

Building Ronja Twister PCB

Building Ronja Twister on PCB

INFO We are going to build PCB twister
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INFO There are two possibilities how to make 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: Box body template

Print out this template and glue on a piece of tin. If you want not to install switches and use internal jumpers instead, strike over the two 6.5mm holes.


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

Option 1: Box lid template

Print out this template and glue on a piece of tin.Gallery[edf]


Option 1: Cutting out

Cut out the outline of the templates. Use a pair of tin cutters. (Note: the photos are of obsolete template used on prototyping). Tattoo the logo using a centre punch and hammer. Keep the strikes consistent. Gallery[ede]
Postscript / PDF / EPS / BIG png / DXF (qcad)

Option 1: Drilling and bending

Drill out and bend the box body and lid according to the print on the template, the plan and photos. Use the 20x20x3 steel L-sections fastened in a vice for bending.
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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 nonporous surface marker for drawing lines. Use square for maintaining perpendicularity and centre punch for making centres of holes. Use the 20x20x3 steel L-sections fastened in a vice for bending the tin.

If you wish to use internal jumpers instead of external switches, do not drill the two 6.5mm holes.

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Soldering corners

Solder corners up using soldering iron, solder and rosin flux. If the box is made of copper, the soldering iron must be big and powerful or use two soldering irons (even they may not suffice) or put the box on cooking stove, fire the cooking stove at appropriate power and perform the soldering on the stove.
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Lid holes

Make holes on the box body by copying them from the lid using a drill. Use 4.3mm drill bit. Use the bolts and maybe nuts to secure the lid on already drilled holes during the operation. Mark the lid so that you can put it back always the same way. Due to drilling imperfections it may be difficult to close up the lid in some other from the total 4 possible positions
Solder the wire into the 3mm hole. If the box is made of copper tin, it is possible it will be impossible to solder with your soldering iron. Either use a stronger soldering iron or two irons at once. If this is not sufficient, place the box on a cooking stove and let the stove heat the box and apply soldering iron on the hot box.


Install one 6mm and three 4mm grommets. (Note: The box on the picture is missing the hole for power connector.)
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Install switches. They have usually a lock against turning, use a tiny file or a small drill to acoomodate the lock.

Power connector

  • Install power connector into the 8.5mm hole next to switches.
  • Solder the outer contact to the box.
  • Solder a 100nF capacitor (C114) between the inner contact and box.
Postscript / PDF / EPS / BIG png / SVG (Inkscape)

Making L stubs

Make 4 L-Stubs:

  • 3 of them according to the picture
  • 1 of them according to the picture but without the insulation

Installing L Stubs

  • Install 3 insulated wire stubs into the grommetss and 1 uninsulated into the 3mm hole next to the grommets to discriminate individual terminals of the terminal block. The sidemost terminals are unused and prevent the terminal block from breaking apart under mechanical stress from the cable.
  • Solder C113 (100nF) on inner end of the L stub which is most away from the uninsulated stub (rightmost on the picture EE5 below). Solder the other end of the capacitor to the box.

Mounting terminal block

Mount the terminal block. Wrench is 5.5mm. Use M3x15 bolts and M3 washers and M3 nuts and tighten.
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Color bands

Apply color bands with shown colors made from duct tape.


Insert LEDs into the box in the same order as in the picture (from left: green, yellow, red). Glue them down using thermal glue pistol.
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STP cable

Cut 1m of the STP cable. Crimp a RJ-45 modular jack best with jacket at the end (recommended wiring: T568B). Strip 50mm of outer insulation from the other (without jack) end of the UTP cable. Strip 5mm from each individual wire. Put the cable through it's grommet-equipped hole (the 6mm grommet in a group of four holes of varying sizes). Adjust the length of unstripped cable between hole and stripped section to 20mm. Fix up the cable in the hole using thermal glue. Seal from both sides, using large amount of the glue. Note: the cable in the picture is not stranded, which is wrong.
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Ribbon cable stubs

Cut the following pieces from stranded ribbon cables:
LengthNumber of wires in a cableNumber of cables (pieces) Note
50mm62Omit if you wish to use internal jumpers
Separate all ends a bit and strip 4mm from all of them.
INFO We are going to solder a PCB. All components will be stuck into their holes according to silkscreen on the PCB and component reference table. Their pins will be soldered using solder and rosin flux. A transformer soldering iron (the one with the loop) or regulated-temperature iron is used for this.

Keep the iron clean by periodical wiping. Use enough flux. The soldering of a joint should go this way: ensure there is enough solder and flux on the iron, put the iron on the joint, wait 3 seconds. During these 3 seconds the solder should automatically spread through the whole joint and make a neat cone. If this doesn't happen, add solder or flux (because something of them is missing, if the temperature of the iron is adequate at least a bit) and repeat. After the 3 seconds, remove the iron.

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You don't need the schematic, it's just for completeness here
  PostScriptPostScript + Gzip PDF
Color Dark twister_01.pdf
Light twister_00.pdf
Small twister_02.pdf
B/W Dark twister_11.pdf
Light twister_10.pdf
Small twister_12.pdf
twister.sch (gschem) Component lists Seznamy součástek

Assignment helper sheet

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

Assembly picture

Print out the assembly picture.


The partlists follow. They will be used during population:

Single-part netlist

Reference designatorDeviceValuePackagePCB Sector
C51CAPACITOR100nceramic 50V, rm 5mm2E
C52CAPACITOR1nceramic 50V, rm 5mm2E
C53CAPACITOR100nceramic 50V, rm 5mm0E
C54CAPACITOR10nceramic 50V, rm 5mm0E
C55CAPACITOR10nceramic 50V, rm 5mm0F
C56CAPACITOR100nceramic 50V, rm 5mm0F
C58CAPACITOR100nceramic 50V, rm 5mm1J
C59CAPACITOR1nceramic 50V, rm 5mm1J
C60CAPACITOR100nceramic 50V, rm 5mm5D
C61CAPACITOR1nceramic 50V, rm 5mm5D
C62CAPACITOR100nceramic 50V, rm 5mm2J
C63CAPACITOR1nceramic 50V, rm 5mm2J
C64CAPACITOR100nceramic 50V, rm 5mm5J
C65CAPACITOR22pceramic 50V, rm 5mm5F
C66CAPACITOR1nceramic 50V, rm 5mm6I
C71CAPACITOR100nceramic 50V, rm 5mm3B
C72CAPACITOR1nceramic 50V, rm 5mm3B
C75CAPACITOR100nceramic 50V, rm 5mm4B
C76CAPACITOR1nceramic 50V, rm 5mm4B
C77CAPACITOR10nceramic 50V, rm 5mm5C
C78CAPACITOR1nceramic 50V, rm 5mm6C
C79CAPACITOR100nceramic 50V, rm 5mm6J
C80CAPACITOR1nceramic 50V, rm 5mm6J
C81CAPACITOR100nceramic 50V, rm 5mm3J
C82CAPACITOR1nceramic 50V, rm 5mm4J
C83CAPACITOR220nceramic 50V, rm 5mm5J
C84CAPACITOR220nceramic 50V, rm 5mm5A
C85CAPACITOR10nceramic 50V, rm 5mm0G
C86CAPACITOR10nceramic 50V, rm 5mm1G
C87CAPACITOR100nceramic 50V, rm 5mm5H
C88CAPACITOR1nceramic 50V, rm 5mm4F
C89CAPACITOR100nceramic 50V, rm 5mm0H
C90CAPACITOR1nceramic 50V, rm 5mm0I
C91CAPACITOR100nceramic 50V, rm 5mm7F
C92CAPACITOR1nceramic 50V, rm 5mm7F
C93CAPACITOR100nceramic 50V, rm 5mm5E
C94CAPACITOR1nceramic 50V, rm 5mm6F
C95CAPACITOR100nceramic 50V, rm 5mm3G
C96CAPACITOR1nceramic 50V, rm 5mm2G
C97CAPACITOR100nceramic 50V, rm 5mm7H
C98CAPACITOR1nceramic 50V, rm 5mm7G
C99CAPACITOR100nceramic 50V, rm 5mm1H
C100CAPACITOR1nceramic 50V, rm 5mm5C
C101CAPACITOR22pceramic 50V, rm 5mm6H
C102CAPACITOR100nceramic 50V, rm 5mm7D
C103CAPACITOR1nceramic 50V, rm 5mm6D
C104CAPACITOR100nceramic 50V, rm 5mm3E
C105CAPACITOR1nceramic 50V, rm 5mm3E
C106CAPACITOR220nceramic 50V, rm 5mm1D
C107CAPACITOR10nceramic 50V, rm 5mm3H
C108CAPACITOR100nceramic 50V, rm 5mm4H
C109CAPACITOR10nceramic 50V, rm 5mm6B
C110CAPACITOR220nceramic 50V, rm 5mm1B
C112CAPACITOR100nceramic 50V, rm 5mm3A
C113CAPACITOR100nceramic 50V, rm 5mmNot on PCB
C114CAPACITOR100nceramic 50V, rm 5mmNot on PCB
CONN52HEADER_VERTICAL2.54mm 4-way 1-rowgold-plated with key4K
CONN53HEADER_VERTICAL2.54mm 4-way 1-rowgold-plated with key3A
CONN55HEADER_VERTICAL2.54mm 2-waygold-plated with keyNot on PCB
CONN56HEADER_FEMALE2.54mm 2-waygold-plated with keyNot on PCB
CONN57HEADER_VERTICAL2.54mm 2-waygold-plated with keyNot on PCB
CONN58HEADER_VERTICAL2.54mm 2-waygold-plated with keyNot on PCB
CONN59HEADER_FEMALE2.54mm 2-waygold-plated with keyNot on PCB
CONN60HEADER_FEMALE2.54mm 2-waygold-plated with keyNot on PCB
CONN61HEADER_VERTICAL2.54mm 6-way 2-rowgold-platedNot on PCB
CONN62HEADER_VERTICAL2.54mm 6-way 2-rowgold-platedNot on PCB
CONN63HEADER_FEMALE2.54mm 6-way 2-rowgold-platedNot on PCB
CONN64HEADER_FEMALE2.54mm 6-way 2-rowgold-platedNot on PCB
CONN65HEADER_FEMALE2.54mm 4-way 1-rowgold-plated with keyNot on PCB
CONN66RJ45 jack with jacketNot on PCB
CONN67HEADER_VERTICAL2.54mm 2-waygold-plated with keyNot on PCB
CONN68HEADER_FEMALE2.54mm 2-waygold-plated with keyNot on PCB
CONN69HEADER_FEMALE2.54mm 4-way 1-rowgold-plated with keyNot on PCB
CONN70HEADER_VERTICAL2.54mm 3-waygold-plated with keyNot on PCB
CONN71HEADER_FEMALE2.54mm 3-waygold-plated with keyNot on PCB
D51LEDGreen5mm diffuse6A
D52LEDYellow5mm diffuse4A
D551N5408  0C
D59LEDRed5mm diffuse1A
R51RESISTOR220250mW pref. metallic2E
R52RESISTOR1.2k250mW pref. metallic5B
R53RESISTOR1k250mW pref. metallic5B
R55RESISTOR3.3250mW pref. metallic2D
R56RESISTOR100250mW pref. metallic1I
R57RESISTOR100250mW pref. metallic1I
R58RESISTOR100250mW pref. metallic2H
R59RESISTOR100250mW pref. metallic1F
R60RESISTOR39250mW pref. metallic2G
R61RESISTOR39250mW pref. metallic1E
R62RESISTOR1.2k250mW pref. metallic5C
R63RESISTOR330250mW pref. metallic2F
R64RESISTOR330250mW pref. metallic4I
R65RESISTOR12250mW pref. metallic1F
R66RESISTOR12250mW pref. metallic4I
R67RESISTOR220250mW pref. metallic1D
R68RESISTOR82250mW pref. metallic0C
R69RESISTOR220250mW pref. metallic4A
R70RESISTOR100250mW pref. metallic2A
S1Switch DPDT ON-ONgold-plated6mm hole6J
S2Switch DPDT ON-ONgold-plated6mm hole3J
U5174HC164 DIL1G
U5274HCT14 DIL4E
U5374HC164 DIL2I
U5474HC32 DIL6I
U5574HC00 DIL3I
U5674HC00 DIL5I
U5774HC04 DIL3D
U5974HC93 DIL5G
U6074HC4040 DIL6G
U6174HC4040 DIL7D
U6374HC164 DIL4D
U6474HC164 DIL2C
U6574HC164 DIL2D
U6674HC133 DIL6F
U6774HC133 DIL7E
U68LM7805  0F

Aggregated partlist

Device Package Value Quantity Reference designator -> PCB sector
1N5408  1
  • D55 -> 0C
74HC00DIL 2
  • U55 -> 3I
  • U56 -> 5I
74HC04DIL 1
  • U57 -> 3D
74HC133DIL 2
  • U66 -> 6F
  • U67 -> 7E
74HC164DIL 5
  • U51 -> 1G
  • U53 -> 2I
  • U63 -> 4D
  • U64 -> 2C
  • U65 -> 2D
74HC32DIL 1
  • U54 -> 6I
74HC4040DIL 2
  • U60 -> 6G
  • U61 -> 7D
74HC93DIL 1
  • U59 -> 5G
74HCT14DIL 1
  • U52 -> 4E
CAPACITORceramic 50V, rm 5mm22p2
  • C101 -> 6H
  • C65 -> 5F
CAPACITORceramic 50V, rm 5mm1n19
  • C100 -> 5C
  • C103 -> 6D
  • C105 -> 3E
  • C52 -> 2E
  • C59 -> 1J
  • C61 -> 5D
  • C63 -> 2J
  • C66 -> 6I
  • C72 -> 3B
  • C76 -> 4B
  • C78 -> 6C
  • C80 -> 6J
  • C82 -> 4J
  • C88 -> 4F
  • C90 -> 0I
  • C92 -> 7F
  • C94 -> 6F
  • C96 -> 2G
  • C98 -> 7G
CAPACITORceramic 50V, rm 5mm10n7
  • C107 -> 3H
  • C109 -> 6B
  • C54 -> 0E
  • C55 -> 0F
  • C77 -> 5C
  • C85 -> 0G
  • C86 -> 1G
CAPACITORceramic 50V, rm 5mm100n24
  • C102 -> 7D
  • C104 -> 3E
  • C108 -> 4H
  • C112 -> 3A
  • C113
  • C114
  • C51 -> 2E
  • C53 -> 0E
  • C56 -> 0F
  • C58 -> 1J
  • C60 -> 5D
  • C62 -> 2J
  • C64 -> 5J
  • C71 -> 3B
  • C75 -> 4B
  • C79 -> 6J
  • C81 -> 3J
  • C87 -> 5H
  • C89 -> 0H
  • C91 -> 7F
  • C93 -> 5E
  • C95 -> 3G
  • C97 -> 7H
  • C99 -> 1H
CAPACITORceramic 50V, rm 5mm220n4
  • C106 -> 1D
  • C110 -> 1B
  • C83 -> 5J
  • C84 -> 5A
  • L51 -> 3B
  • U69 -> 7B
  • CONN51 -> 1K
  • U58 -> 1H
  • U62 -> 3G
HEADER_FEMALEgold-plated2.54mm 6-way 2-row2
  • CONN63
  • CONN64
HEADER_FEMALEgold-plated with key2.54mm 2-way4
  • CONN56
  • CONN59
  • CONN60
  • CONN68
HEADER_FEMALEgold-plated with key2.54mm 3-way1
  • CONN71
HEADER_FEMALEgold-plated with key2.54mm 4-way 1-row2
  • CONN65
  • CONN69
HEADER_VERTICALgold-plated2.54mm 6-way 2-row2
  • CONN61
  • CONN62
HEADER_VERTICALgold-plated with key2.54mm 2-way4
  • CONN55
  • CONN57
  • CONN58
  • CONN67
HEADER_VERTICALgold-plated with key2.54mm 3-way1
  • CONN70
HEADER_VERTICALgold-plated with key2.54mm 4-way 1-row2
  • CONN52 -> 4K
  • CONN53 -> 3A
LED5mm diffuseGreen1
  • D51 -> 6A
LED5mm diffuseRed1
  • D59 -> 1A
LED5mm diffuseYellow1
  • D52 -> 4A
LM7805  1
  • U68 -> 0F
  • C111 -> 1B
  • C57 -> 1C
RESISTOR250mW pref. metallic3.31
  • R55 -> 2D
RESISTOR250mW pref. metallic122
  • R65 -> 1F
  • R66 -> 4I
RESISTOR250mW pref. metallic392
  • R60 -> 2G
  • R61 -> 1E
RESISTOR250mW pref. metallic821
  • R68 -> 0C
RESISTOR250mW pref. metallic1005
  • R56 -> 1I
  • R57 -> 1I
  • R58 -> 2H
  • R59 -> 1F
  • R70 -> 2A
RESISTOR250mW pref. metallic2203
  • R51 -> 2E
  • R67 -> 1D
  • R69 -> 4A
RESISTOR250mW pref. metallic3302
  • R63 -> 2F
  • R64 -> 4I
RESISTOR250mW pref. metallic1k1
  • R53 -> 5B
RESISTOR250mW pref. metallic1.2k2
  • R52 -> 5B
  • R62 -> 5C
RJ45jack with jacket 1
  • CONN66
Switch DPDT ON-ON6mm holegold-plated2
  • S1 -> 6J
  • S2 -> 3J
Postscript / PDF / EPS / BIG png / Gerber RS274-X (gerbv)

Sector marks

If you have revision 20051007 or earlier, you don't have sector marks on the edges. Use a ruler and permanent marker to draw the marks by 1cm.


Solder the parts into PCB in this order:
  • IC sockets (if you are using them)
  • Resistors
  • Diodes
  • All IC's except U68, if you are not using sockets
  • Polarized capacitors
  • Capacitors except C54, C55, C113, and C114
  • CONN-designated connectors (51, 52, 53) with key oriented according to assignment helper sheet
  • instead of LEDs D51, D52, D59 solder the connectors called "Header vertical, pitch 2.54mm, gold plated, 1-row, 2-way, with key" with key oriented according to the assignment helper sheet
  • On places S1, S2 solder the connectors called "Header socket, 2-row, 2.54mm pitch, 8.3mm depth, gold-plated, 6-way". You'll obtain them from "Header socket, 2-row, 2.54mm pitch, 8.3mm depth, gold-plated, 14-way" by cutting apart.
  • Instead of U68, "Header vertical, pitch 2.54mm, gold plated, 1-row, 3-way, with key" according to assignment helper sheet
  • Coil

Bug fix

If the revision of PCB is 20040408 and earlier (check directly on the printed circuit board), perform a bug fix according to the picture. Scratch out the green soldermask on the adjacent plane and connect with pin as marked by red line.

The bug is harmless and has none or unnoticeable impact on the performance of the device. If you are having other pieces of Twister with this bug already built into a case, do not bother with disassembly. Revision 20040807 has the bug already fixed.


Pour the isopropyl alcohol into the rectangular pan and dip the PCB into it, components pointing upwards. Leave it there for half an hour. Then brush all the rosin flux off with toothbrush, wash again in the isopropyl alcohol, dip off and let dry up.
Postscript / PDF / EPS / BIG png

Correctness check

Take the PCB and inspect it completely for:
  • Left-out components (except C54, C55, C113, and C114)
  • Correct values
  • Correct IC types
  • Correct orientation of IC's
  • Correct orientation of diodes.
  • Correct orientation of polarized capacitors
  • Correct orientation of connector keys
  • Joints soldered wrong or not at all

Printing this partlist and another copy of assembly plan (left) will help for scratching out.



What do you think would happen if you skip this correctness check? "Your board would come to a screeching halt and you'd fly. And you'd smash cement." -- Stacy Peralta, Dogtown and Z-Boys"
Postscript / PDF / EPS / BIG png / SVG (Inkscape)

(Optional) jumpers

If you decided to use jumpers, jumper the board.

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

Wiring connectors

Attach connectors (except those for switches if you decided to use internal jumpers instead) using the cable stubs from ribbon cable you have already made. You can use insulating tube if you want to have it neater :)

Solder CONN52 connector the same way on the free end of the TP cable. Twist the remaining 4 unused conductors together and solder them to the ground pin of the power connector as seen in the photo, maybe using a piece of additional wire. Keep this connection as short as possible so it also secures the cable mechanically against pulling out.


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


Solder the C54 and C55 (both are the same value) directly on the pins of U68. Mount U68 using one short M3 bolt, one M3 toothed spring washer and one M3 nut onto it's hole from the inner side, it's pins pointing towards the four big holes (connectors & switches).



Mounting bolts

Insert the long M4 bolts into the four holes for holding the PCB. Put a toothed spring washer on each one and tighten up with M4 nut. Put another M4 nut and adjust the height of the nut so that the distance between future PCB and the box will be 13mm.


Put the PCB inside. Adjust the M4 nuts so the PCB sits on 4 points and not only on 3. Put M4 washers over it, M4 sprint washers, M4 nuts and tighten down. Put the lid over and close with two bolts and save the remaining 8 nuts and 8 bolts. The lid will be tightened down as soon as the Twister is tested.
Postscript / PDF / EPS / BIG png / SVG (Inkscape)


Print out the Twister label. Stick the label on the outer side of the lid and fill in.

Print out the small schematic (see the Schematic 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.

An expected information missing here?