Prototyping: Custom extended numpad (31 key)

[metalliqaz]

If you're Nathan from Costa Mesa, PM me to get your tracking number

[MOZ]

Invoice sent to jdcarpe, Pacifist, hakfoo and nubbinator for @ $22.

jdcarpe, Pacifist, nubs have been discounted $3 since I have to ship them some stuff, so they saved on some shipping.

jdcarpe and my case will have the slightly broder mid section, for everyone else the case will be uniform.

If someone still wants the case or wants to make changes, they can still be done by Friday this week as my exams have been rescheduled so I couldn't get the cases cut yet.

[Pacifist]

Invoice sent to jdcarpe, Pacifist, hakfoo and nubbinator for @ $22.

jdcarpe, Pacifist, nubs have been discounted $3 since I have to ship them some stuff, so they saved on some shipping.

jdcarpe and my case will have the slightly broder mid section, for everyone else the case will be uniform.

If someone still wants the case or wants to make changes, they can still be done by Friday this week as my exams have been rescheduled so I couldn't get the cases cut yet.

Sweet. I may change one color in my case, so I have until friday to change the order?

Hopefully this comes after the 20th cuz I have so much homework.....

[nubbinator]

Just installed all the diodes in my PCB.  Now I can't wait to assemble it and test it out.  I may just have to go get some wood and laser cut the top and bottom so I can at least get the switches installed.

I'm also debating flipping the LEDs around and installing them underneath so I get a glowing effect through the frosted clear plexi or going with a SIP mod so I can swap the colors.  Decisions decisions.

[Pacifist]

Just installed all the diodes in my PCB.  Now I can't wait to assemble it and test it out.  I may just have to go get some wood and laser cut the top and bottom so I can at least get the switches installed.

I'm also debating flipping the LEDs around and installing them underneath so I get a glowing effect through the frosted clear plexi or going with a SIP mod so I can swap the colors.  Decisions decisions.

I'm going with the solderless headers. But the glowing effect sounds good too.

[Pacifist]

I noticed that the switches for the vertical 2X keys are sideways compared to the other keys. On my g80, those sideways vertical keys are also sideways. Cherry keys stems are not perfectly the same size, so there could be problems with the stems. Is this an accident, or are we supposed to use specific caps?

[metalliqaz]

I noticed that the switches for the vertical 2X keys are sideways compared to the other keys. On my g80, those sideways vertical keys are also sideways. Cherry keys stems are not perfectly the same size, so there could be problems with the stems. Is this an accident, or are we supposed to use specific caps?

Any caps will fit.  Caps not made for the 2x vertical will be tighter than usual, but it's no big deal.

[regack]

I'm also debating flipping the LEDs around and installing them underneath so I get a glowing effect through the frosted clear plexi or going with a SIP mod so I can swap the colors.  Decisions decisions.

Is there enough space underneath to do that? 

How about instead, you install BOTH...  mount the SIP headers in the switches for the top half, then use some 0805 LEDs across the pads on the underside of the board.   Of course, you'll be wiring the LEDs in parallel, so you'll have to account for that, and if you ever remove the ones from the top, that could cause some problems... anyway, uhh, have fun with that

[Hak Foo]

Is there a "Lamp test mode" in the software package?

I'm waiting on a case to construct it fully, but I figure I can install the diodes and LEDs and test for functionality/correct polarity while I wait.

[Pacifist]

I noticed that the switches for the vertical 2X keys are sideways compared to the other keys. On my g80, those sideways vertical keys are also sideways. Cherry keys stems are not perfectly the same size, so there could be problems with the stems. Is this an accident, or are we supposed to use specific caps?

Any caps will fit.  Caps not made for the 2x vertical will be tighter than usual, but it's no big deal.

Cool. Wanted to make sure, this is my first numpad.


Also Moz, I paid the invoice for the case. I may change one color and if so I will let you know 2morrow

[metalliqaz]

Is there a "Lamp test mode" in the software package?

I'm waiting on a case to construct it fully, but I figure I can install the diodes and LEDs and test for functionality/correct polarity while I wait.

You can't install LEDs before you install the switches, but you can do what I did when I tested them after soldering.  Just plug it in and it will turn on all the backlights by default.  Then you can just touch the LED holes with the leads of an LED to test it.  Once you've installed the diodes, you can just short the switch holes with some metal and it will actuate.

[Pacifist]

Is there a "Lamp test mode" in the software package?

I'm waiting on a case to construct it fully, but I figure I can install the diodes and LEDs and test for functionality/correct polarity while I wait.

You can't install LEDs before you install the switches, but you can do what I did when I tested them after soldering.  Just plug it in and it will turn on all the backlights by default.  Then you can just touch the LED holes with the leads of an LED to test it.  Once you've installed the diodes, you can just short the switch holes with some metal and it will actuate.

0.0 that's what I did yesterday....and this is my first time using a bare PCB...

[Pacifist]

I'm going to buy some stabs from imsto, it costs $10 for 6 2X plus the spacebar stabs, and then the $10-15 for shipping. Does anyone want to group up with me for the orders to save on shipping? I'm also buying two packets of cleaning goo and some O rings

Also moz do you have red acrylic or is it just pink?

[MOZ]

I'm going to buy some stabs from imsto, it costs $10 for 6 2X plus the spacebar stabs, and then the $10 for shipping. Does anyone want to group up with me for the orders to save on shipping? I'm also buying two packets of cleaning goo and some O rings

Also moz do you have red acrylic or is it just pink?

I needed some red translucent acrylic for some other work, so I have that.

[Pacifist]

I'm going to buy some stabs from imsto, it costs $10 for 6 2X plus the spacebar stabs, and then the $10 for shipping. Does anyone want to group up with me for the orders to save on shipping? I'm also buying two packets of cleaning goo and some O rings

Also moz do you have red acrylic or is it just pink?

I needed some red translucent acrylic for some other work, so I have that.

Oh sweet. Can you change my middle pink layer to red? Thank you so much!

And translucent too! Even better

[MOZ]

I'm going to buy some stabs from imsto, it costs $10 for 6 2X plus the spacebar stabs, and then the $10 for shipping. Does anyone want to group up with me for the orders to save on shipping? I'm also buying two packets of cleaning goo and some O rings

Also moz do you have red acrylic or is it just pink?

I needed some red translucent acrylic for some other work, so I have that.

Oh sweet. Can you change my middle pink layer to red? Thank you so much!

And translucent too! Even better

Got it.

[Pacifist]

I'm going to buy some stabs from imsto, it costs $10 for 6 2X plus the spacebar stabs, and then the $10 for shipping. Does anyone want to group up with me for the orders to save on shipping? I'm also buying two packets of cleaning goo and some O rings

Also moz do you have red acrylic or is it just pink?

I needed some red translucent acrylic for some other work, so I have that.

Oh sweet. Can you change my middle pink layer to red? Thank you so much!

And translucent too! Even better

Got it.

Thanks! 

[TacticaT]

I assume a premature question since everyone doesn't seem to have all their v1 / prototype units put together yet, but…


Will there be another run? A post from a long time ago said it was a one-time deal, but it never hurts to ask...

[Pacifist]

I assume a premature question since everyone doesn't seem to have all their v1 / prototype units put together yet, but…


Will there be another run? A post from a long time ago said it was a one-time deal, but it never hurts to ask...

most likely not. metaliqaz's other project, the epsilon 75%, never had a r2. you can download his files and have a pcb made yourself

[metalliqaz]

There are still some left. If you want one just PM

[Pacifist]

welp moz still hasn't gotten the cases out

tempted to just solder on the switches but I don't have a desoldering pump

@metalliqaz, how is the pad so far?

[metalliqaz]

welp moz still hasn't gotten the cases out

tempted to just solder on the switches but I don't have a desoldering pump

@metalliqaz, how is the pad so far?

I really like it.  The primary concept was the two thumb buttons next to the primary cluster.  Even though it isn't tilted to an "ergonomic" angle like the ergodox, I find that it is perfectly comfortable and feels like the natural position.

I haven't really used the macro buttons that I have assigned above the space and tab thumb keys, to be honest.  However the backlighting is nice and gets plenty of compliments.

[SpAmRaY]

welp moz still hasn't gotten the cases out

tempted to just solder on the switches but I don't have a desoldering pump

@metalliqaz, how is the pad so far?

Just an FYI moz stated elsewhere he won't be back in India until the middle of February.

[Pacifist]

welp moz still hasn't gotten the cases out

tempted to just solder on the switches but I don't have a desoldering pump

@metalliqaz, how is the pad so far?

Just an FYI moz stated elsewhere he won't be back in India until the middle of February.

yea I know.

[MOZ]

I was building my QazPad today and noticed a big mistake I have made in the case, I left space in the case for a 120mmx120mm PCB, whereas as the PCB is actually 124mm.

I don't know where the screw up happened, I didn't have the PCB, nobody double checked my design; only explanation I have is, for all cases I have made thus far, the PCB was always 19.05mm*number of switches in length and breadth. This was not the case here, not blaming anyone, but a miscommunication has happened. Now, this renders the already cut cases pretty much useless.

Current pckages are packed and labeled and ready to send, which I will still do tomorrow.

So what do we do from here, really sorry for the mishap.

[metalliqaz]

Oh no!

Yes, there is a border around the switches on the PCB.  It was made to strengthen the PCB stabilizer mounts, and I just wanted to make it square.  When I get home I can check the provided DXF files, but I'm pretty sure they're right.  Also I know with certainty the Gerbers are correct.

Now, the question is, can we cut down the PCBs?  I will have to go back and check the design.  Obviously if there are traces in that region, then we can't.  2mm from each side isn't much.  Although, the FRC is also very difficult to modify without totally destroying it.

Moz, I wouldn't worry about the mistake so much.  We'll figure something out.  I made two pretty big design errors myself!  I was able to work around them with some ugly, ugly soldering.

[jdcarpe]

From the image in the OP, there is a trace along the top edge of the PCB in that area. And cutting from the bottom would cut into the stabilizer holes.

[MOZ]

Let's see what comes out to be the best solution, worst case scenario is I will have to get new cases cut.

[metalliqaz]

Not even entire new cases, just the part that is at the same level as the PCB.  The rest of the layers don't have to change.

[MOZ]

Not even entire new cases, just the part that is at the same level as the PCB.  The rest of the layers don't have to change.

I think they do, reason is since the PCB requires 2mm extension on all sides, and we use the same base and top (case was 5 layers, 3 iddle, base and top), screw hole positions must remain same, it means the inner wall between bolt holes and PCB edge will get dangerously thin on the middle layers.

[metalliqaz]

Oh, right

[Pacifist]

Got the qazpad case today

And yes its too small

Moz what is your plan for the new cases? I am willing to pay for the new case to be made.

Meanwhile I can do some kind of direct solder project with the case )

[MOZ]

I can get new cases cut, priced slightly lower at $20, without any of the hardware (Stand-offs, screws, rubber feet) since you already have them.

If everyone is cool with it, we can get this done with real quick.

[Pacifist]

I can get new cases cut, priced slightly lower at $20, without any of the hardware (Stand-offs, screws, rubber feet) since you already have them.

If everyone is cool with it, we can get this done with real quick.

I'm cool with that. Just make sure they work with your own pcb )

[MOZ]

Haha, I sincerely have no idea what went wrong in the previous design, and it is the first time I have had such an issue with any of the cases I have designed thus far. I will quadruple check this time to make sure all the dimensions are correct before producing the final version.

[metalliqaz]

I missed the post today so I'll not have a look until Monday.  I'm going to try and hack it. Nothing to lose, really.

[MOZ]

You do have two cases to experiment with

[Pacifist]

I missed the post today so I'll not have a look until Monday.  I'm going to try and hack it. Nothing to lose, really.

Sweet, if it works, please let us know.

It should work, as the pcb pretty much goes flush to the hex bolts. But I don't have the proper tools to make cuts that precise to mod my case for now

[Pacifist]

Uh so I was putting on PCB mounted cherry stabs. For all the stabs except the inner stab on the "extended"  part of the numpad the holes are in the wrong direction. The big holes are the sides with the wire, and with PCB mounted stabs, the stab wire goes in the position of the diode. I broke a diode trying to put the stab in with these holes. Tried reversing it but alas pcb mounted stabs don't like it that way.

Anyways, I was fiddling around with the board and realized that if you just completely take out the second to top layer, you can get the whole thing put together. Its a bit tight and ugly having that empty space, but it works. The PCB sits on the middle layer.

[Hak Foo]

That's exactly what I ended up doing... two layers, the PCB, then the other layers.






The clean features make it look like a baby Quickfire XT... and I really need to dust said XT.

I'll have to throw some 2x caps on the keys and see if it's gonna be necessary to add stabilizers; I hope, if necessary, I can add platemount stabilizers after the fact.

[Pacifist]

oh **** sweet

I'm going to go for two layer PCB then plate (if it fits). Looks great hak foo, I'll try to get mine built soon

moz, I probally won't need to get a new case seeing that this method works

[MOZ]

Interesting, I think maybe we can get the missing layer done only. The inner part between the standoff hole and the edge will be thin,  but the pressure from the layers below and above should hold it in place. Time to do some experiment.

[metalliqaz]

Uh so I was putting on PCB mounted cherry stabs. For all the stabs except the inner stab on the "extended"  part of the numpad the holes are in the wrong direction. The big holes are the sides with the wire, and with PCB mounted stabs, the stab wire goes in the position of the diode. I broke a diode trying to put the stab in with these holes. Tried reversing it but alas pcb mounted stabs don't like it that way.

Anyways, I was fiddling around with the board and realized that if you just completely take out the second to top layer, you can get the whole thing put together. Its a bit tight and ugly having that empty space, but it works. The PCB sits on the middle layer.

The hits keep on coming! *facepalm*  the solution will be to install those diodes upside-down

[Pacifist]

Uh so I was putting on PCB mounted cherry stabs. For all the stabs except the inner stab on the "extended"  part of the numpad the holes are in the wrong direction. The big holes are the sides with the wire, and with PCB mounted stabs, the stab wire goes in the position of the diode. I broke a diode trying to put the stab in with these holes. Tried reversing it but alas pcb mounted stabs don't like it that way.

Anyways, I was fiddling around with the board and realized that if you just completely take out the second to top layer, you can get the whole thing put together. Its a bit tight and ugly having that empty space, but it works. The PCB sits on the middle layer.

The hits keep on coming! *facepalm*  the solution will be to install those diodes upside-down

Yea that's what I figured. Already desoldered and resoldered.

Moz, I'm sure the pressure will hold it in. Also, that section has nowhere to go, so it should stay in place with minimal wobble

Another issue with pcb mounted stabs is because the plate is so thick, the stabs don't let the plate go down enough and the switch lies a little too high. I can still solder in switches no problems, but its not sitting like it should. Its minor, as the stabs can still work with the higher switches, so I don't think it'll be an issue

[MOZ]

That is a known issue and was discovered by whiskytango for the ghpad.

Since this case was made after that, the error could not be corrected.

I actually made a thread on this topic when I started designing acrylic plates, the interaction of acrylic plates and stabilizers.

[Pacifist]

Its nothing too bad. As long as the acrylic plate holds the switches solid enough, it'll work

Thanks for all your hard work Moz on making cases for all these projects.

[Pacifist]

Oh yea

bottom layer, 2nd to bottom, PCB, open air, top layer. Not very structurally sound but works

[MOZ]

Need side view

[Pacifist]

http://imgur.com/a/trXLE

[Pacifist]

Ok I figured out the optimal way to do everything. After doing the previous design as pictured, I realized there was a huge gap between the plate and PCB and I had an extra layer in the middle that I decided to go without to make the whole thing sit lower. As the plate was already soldered, I broke the layer in half, stuck it between the pcb and plate, and then reassembled. Now its plate layer pcb layer bottom with almost no air and feels very solid. I will post pictures tomorrow but I'm satisfied for everything except this cut in one layer (which is minor but slightly annoying as I suck at cutting things)