Highway 89 - Build in progress

[O]

With the long weekend here, I decided to try my hand at making a layout and building the Hwy89. I started the layout attempt about 5 different times until I came up with something compact enough to fit in a 1590B along with the 4 pots. I'm still tweaking the layout, so when it's ready (and if someone wants it) I'll post it.

Anyway, since I'm used to the inkjet paper method of making a pcb, I decided to take some pics of the progress.



Here is the PCB right after I finished ironing on the inkjet glossy paper. The printer is an old Okidata OL-400e that has a max resolution of 300x300. I was actually impressed with the resolution out of this old printer. The layout was done in ExpressPCB. With the glossy paper method, how you prep the copper board is very crucial. I sanded the paper with 250 grit wet/dry sandpaper dipped in acetone. I then moved on to 000 steel wool and then finished up with an acetone bath to get rid of any grease. I usually use Naphta, but since I was out, Acetone was next in line.



Here the board has already been etched and I'm just holding it up to a light source to see if there are any unetched traces. I try to etch with fat traces whenever I can. You save a lot of etchant when you use thicker traces since there's less copper to etch. I put the etchant in a ziploc baggie and then into a very hot bowl of water and started agitation. After about a minute, the board was ready.



Lacquer thinner was used to dissolve the toner. Once again, the board is double checked for unetched traces and sadly, over etched sharpie-retouched places.



Board is drilled and ready to go. A multi-speed Dremel mounted on a Craftsman dremel drill press was used. You will notice that there are 2 different sized holes. The smaller diameter holes are for the normal components and the larger holes are for the wires.



The board is now semi-populated. I'm missing a few resistors and a few caps (Mouser order scheduled for next week!) The board needed a few parts re-aligned and resized, but other than the tight fit, it's one of my best layouts to date IMHO.



Back shot showing the soldering. One thing I noticed is that it's really easy to solder onto the filled plane if you're not careful. Once you get past the few first components, you start getting the hang of it. I'll probably put both versions of the layout (non-filled plane and a filled plane like this board) on the pdf.

Check back for further developments in the coming days. I have big plans for this build and I hope I can make those plans a reality.

[ulysses]

that looks nice

what software did you use to create the layout?

cheers
ulysses

[O]

that looks nice

what software did you use to create the layout?

cheers
ulysses

Thanks! I used ExpressPCB. The program is really easy to use, but you have to edit or create your own components since the default components' holes aren't big enough for diy drilling.

[O]

I'm almost done with the PDF for this project. Anyone interested in the PCB layout? (ready to print)

[Barcode80]

i am! been meaning to make this one for some time... only problem is that now i can't seem to get in touch with doug to get the schem values.

[slacker]

No need to get in touch with Doug, it's all out in the open now, http://www.diystompboxes.com/smfforum/index.php?topic=55812.0

[markm]

Nice!
Layout is tight but looks real good.
I went for the larger approcah when I did mine! 
Great Job O!

[O]

I was going to go with a bigger layout (that's why I had to restart this last one). The original plan was to put it in a sideways 1590BB box that I bought all drilled up. As I thought about it some more, I decided to go for a 4 knob 1590B box (think Zendrive) to save space on my pedal board.

I'm trying to finish up the layout and pdf and schem all in one (like FP does over at TonePad) I'm going to test printing it out to see if the resolution is correct. If it is (and I think it's right), then I'll attach the pdf to this post later tonight (hopefully).

[O]

Small update - I was finally able to get the rest of the parts to complete the circuit. I also worked out the knobs/pots layout so that it would fit without needing a shoehorn to get all the stuff inside the 1590B enclosure.


Here's the box drilled and waiting (I really need to get a drill press).


Box fully loaded. It was a challenge to get all the components inside, but in the end, all the parts ended up fitting (although a bit snug).


Other side...


Obligatory gut shot...


Semi rat's nest

I am actually going to paint this pedal, but I wanted to fully test it tomorrow (band practice). I'll update the thread once the painting process starts. I ran into a problem with the layout so I had to redo some parts placement and wiring. The new layout is actually smaller than the one I show here. I'm re-writing the schematic to include in the pdf. I haven't noticed much interest in the PCB layout, so I'm not really putting much effort in it. If someone does want it, I'll keep working on it.

That's all for now...

[Auke Haarsma]

that must have been a real challange! Nice work!

[momo]

I did this build and reported that it sounded OK, but not much more than a regular distortion....I had NOT tryed it in my amp. This pedal is awsome!, cleans up nicely with guitar pot, and has great tones.

[O]

I did this build and reported that it sounded OK, but not much more than a regular distortion....I had NOT tryed it in my amp. This pedal is awsome!, cleans up nicely with guitar pot, and has great tones.

This build has got to be one of the most responsive OD/Distortion pedals I've ever tried. Doug wasn't kidding when he said that it cleans up real nice when you adjust the volume knob on your guitar.

I have a little Marshall M2 (the clip-on, little practice amp) and over the years, I've tried out every pedal on that amp. I can now accurately gauge what a pedal will sound like on my normal sized amps. If the pedal sounds good through a crappy 8 inch speaker, then it sounds amazing through a Blues Deluxe 4x10 or a H&K Anniversary tube amp. Well, the Hwy89 blew my ears off when I plugged it into the Marshall amp, so I can't wait to plug in to my BD 4x10 tonight.

Thanks Pong, I'm going to start the painting process hopefully tonight.