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.

Option 1: Box lid template

Print out this template and glue on a piece of tin.

Option 1: Cutting out

Option 1: Drilling and bending

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.

Soldering corners

Lid holes

Grommetss

Switches

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.

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

Color bands

LEDs

STP cable

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.

Assignment helper sheet

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

Assembly picture

• D55 -> 0C

• U55 -> 3I
• U56 -> 5I

• U57 -> 3D

• U66 -> 6F
• U67 -> 7E

• U51 -> 1G
• U53 -> 2I
• U63 -> 4D
• U64 -> 2C
• U65 -> 2D

• U54 -> 6I

• U60 -> 6G
• U61 -> 7D

• U59 -> 5G

• U52 -> 4E

• C101 -> 6H
• C65 -> 5F

• 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

• C107 -> 3H
• C109 -> 6B
• C54 -> 0E
• C55 -> 0F
• C77 -> 5C
• C85 -> 0G
• C86 -> 1G

• 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

• C106 -> 1D
• C110 -> 1B
• C83 -> 5J
• C84 -> 5A

• L51 -> 3B

• U69 -> 7B

• CONN51 -> 1K

• U58 -> 1H

• U62 -> 3G

• CONN63
• CONN64

• CONN56
• CONN59
• CONN60
• CONN68

• CONN71

• CONN65
• CONN69

• CONN61
• CONN62

• CONN55
• CONN57
• CONN58
• CONN67

• CONN70

• CONN52 -> 4K
• CONN53 -> 3A

• D51 -> 6A

• D59 -> 1A

• D52 -> 4A

• U68 -> 0F

• C111 -> 1B

• C57 -> 1C

• R55 -> 2D

• R65 -> 1F
• R66 -> 4I

• R60 -> 2G
• R61 -> 1E

• R68 -> 0C

• R56 -> 1I
• R57 -> 1I
• R58 -> 2H
• R59 -> 1F
• R70 -> 2A

• R51 -> 2E
• R67 -> 1D
• R69 -> 4A

• R63 -> 2F
• R64 -> 4I

• R53 -> 5B

• R52 -> 5B
• R62 -> 5C

• CONN66

• S1 -> 6J
• S2 -> 3J

Sector marks

Soldering

• 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.

Correctness check

• 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.

Warning

(Optional) jumpers

If you decided to use jumpers, jumper the board.

Wiring connectors

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.

Regulator

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

Completion

Labels

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.