Tutorial - Building Pedals Ffrom Zero to Rock

[edy_wheazel]

 Disclaimer nr.1 - english is not my native language, so please bare with me.
Disclaimer nr.2 - some of the methods described may differ from the methods you use. Depending on situation I also use different methods, like photo method etching, different engraving method, etc...
Disclaimer nr.3 - this is a tutorial made especially for beginners.

Step 1 - Choosing a schematic

The internet is full of schematics, but some of those might be wrong or might contain mistakes. So, if the schematic isn't 100% verified use your friend the breadboard. It's a nice friend to have around, you can tweak the values of some components until you find that special tone you like.
Try not to use a schematic containing components discontinued since Khrushchev and Kennedy were playing Red Alert in Cuba, lots of shematics out there with available components, also cheaper. Experiment with what you have available.
The schematic chosen for this tutorial is Maxon OD808, a nice overdrive.



Many schematics come with the pcb layout, but usealy I prefer to do my own.

Step 2 - Components

Before you start designing your pcb it's better to have your components ready, this way you know their exact dimmension.



Step 3 - Desining your pcb

One of the reasons I design my own pcb is to place the pot's directly on the board, this way I don't have wires.



Step 4 - Transfering the pcb

In this tutorial I used glossy paper from commercials spamming my mailbox. I don't use them anymore, now I use cheap photo paper, it's much easyer to peel and the tranfer is better.



First I print the pcb on a normal paper, then, on top of it I put the paper (glossy magazine or phote) on which the design will be. This is not necesary, but I'm cheap and I don't want to waste photo or glossy paper.
Take a piece of "blank" pcb and meke it shine so you can see your reflection on it. Try not to put your fingers on it after that.



Place your paper on top of the pcb and use the pcb on a piece of wood. Don't put it directly on your table if you don't want any trouble with your wife/mom.



Start ironing. Don't press too hard or your wide traces will became wider. You can see the tonner sticking to the pcb, iron the board for around 3 minutes. After you're done let the board cool, this is important. If you use glossy paper soak it in water and peel the paper off. If you use photo paper soaking is not required, you just peel it off. Use a marker if necessary to enforce weak or discontinued traces.



As I said, I don't use glossy paper anymore, with photo paper the results are like this:



After you check the traces a few times it's etching time! I use Fe2Cl3.



The board after etching:



Step 5 - Placing the components

First clean the toner, for that I use very fine sand paper. Then it's drilling time!



I use some resin disolved on technical alcohol for the traces. This way the soldering flux sticks muck better to the board.



Place the components. To protect the traces I cover them with flux.





Check again the connection and test the board. To test the board I use this connectors:





Don't use multiple ground wires, only one. Trust me on this!

Step 6 - The enclosure

Before you drill the enclosure mark the place where the holes will be. Check the dimmension of the switches and plugs and after that check again.



Drill the enclosure:



Place the jack and switch/switches inside:



Check the lenght of the wires and place the board inside:



Wire the pedal and test it:



Step 6 - Engraving the enclosure

This is one of the methods I use for simple designs. The advantage is that the etching is very deep but you can't make too many details with this method.
First, clean the enclosure using very fine glass paper (2000) and print your design.



Cover the enclosure with adhesive paper used in construction to protect the surfaces:



Place the design on top and using a sharp cutter cut the design:




 


Watch your fingers with the cutter! The tip of the cutter must be wery sharp, otherwise the paper will crumble.

To etch the enclosure you can dip it face down in Fe2Cl3 or use my method involving my kid's silly putty. Don't use concentrated Fe2Cl3, I use what remains after etching pcb's (I told you I'm cheap!).

 





Clean the enclosure and polish it.



There is off course the classical method of etching with a laser printer:



Drill the hole for the LED and put the pedal together.



Quick demo. I'm not a guitar player, this is why it sounds crappy.