[opensource] TOAD v2 | 70% keyboard | Now with Alps and aluminum case.

[TalkingTree]

Ladies and gentlemen, v2 is finally ready.
This is a follow-up to the original TOAD. I'm posting a new thread because the project has been since entirely reworked.
Everything from PCB to plate to case will be opensource, hoping that you'll find it useful.


Part 1: PCB

PCB has reached its third revision and it now features ALPS and MX support, two LED indicators and a universal layout, as shown in the next post.
Once again I owe this achievement to the good fellows who taught me designing PCBs, bpiphany, pomk and vvp. I can't express my gratitude to you gentlmen enough.





Soldered all the SMD components.



Part 2: Plate

Plates were again designed with swill's builder, which allowed me to draw them in a few minutes. Without this great tool I would still be trying to figure out what to do in Inkscape.
Pwner and xondat's experience and expertise truly came to help to fine tune the plate and I do appreciate their suggestions. Thank you guys.
I then had the plates laser cut out of brushed stainless steel 304 at Shangai AnAng Automatic Equipment.




And finally everything was assembled with Kailh Box Black switches.



Part 3: Case

Designing a case was a massive but fun task. For the first version of the TOAD I went through a lot of different options for both shape and material, yet, as you know, I eventually opted for a 3D printed case made out of PLA.
Then this comment really made me wanna try something new.

Lovely. Needs an aluminum case though )

Hence, I switched from Tinkercad to Fusion 360, for the latter was more suitable to my new needs and, nonetheless, free for an hobbyist like me.
I wanted something not too gaudy and the KB-6251 was simply perfect for this task, especially for the bottom half.
Obviously I knew nothing about parametric modeling so I browsed YouTube for some tutorials and Lars Christensen's were undoubtedly the most appropriate. After a few weeks spent in front of my computer, I finally ordered the case at Ulitemech.
I spammed F5 on DHL tracking website for the past fourtyeight hours, literally, waiting for my new case to be delivered, then this package showed up.



I gently unwrapped the package with care, hoping the the customs inspector did the same, and this is what popped out of the box.




I noticed I forgot the screw heads holes for bottom half but I could do without as the plate is perfectly clamped by the two halves of the case.




I applied some rubber feet at the four holes that I predisposed.


Tested the case with the plate.


Finally I had everything ready for the final assembly.


And here it is.


Part 4: Layout, Firmware, Switches, Keycaps and final result.

For a change, I moved to a new encoding, which is Italian 142, and this is how my new layout is organized.
I'm using the TOAD with EasyAVR v3.00.01. Big thanks to metalliqaz for this great tool.
I installed Kailh Box Black which are easily my new favourite switches.
I mixed keysets to resemble the Italian 142 encoding, therefore I used dye sub italian PBT keycaps from a G81/SAI; some german dye sub PBT keycaps from a G81/SAD, specifically I used numbers from 7 to 0, the letter Q and the *+~. Strg and °^ are there just for fun.
Backspace, Right Shift and Fn key are from wodan's GMK HADapter & HADditionals kit.
ANSI Enter is a PBT dyesub and it's from Shadovved's EnjoyPBT Dyesub/Blank Keysets.
R1 Delete key is from the 1800 kit of xiaodian317's GMK Classic Retro & GMK GEEKHACK Pack.
I plan to have some custom dye sub beige keycaps to complete the 142 but it will be done later on.
I'm also planning to design a dust cover which will be likely made out of transparent 3D printed plastics.
For those wondering, the whole keyboard weighs roughly 1900 grams.



I really like how pinholes work for LED indicators.




And finally, a typing test.

Thanks for reading.

[TalkingTree]

This post contains everything that is needed to assemble your own TOAD.

PCB
PCB source is available here. Please use rev. 3.

Parts list.

Quantity	Description	Manufacturer part number	Symbol
1	TOAD PCB
1	Atmel ATmega32u4	ATMEGA32U4-AU	U1
1	16MHz crystal	X322516MOB4SI	X1
2	22pf capacitor	CL21C220JBANNNC	C1, C2
78	1N4148 diode	1N4148W (1N4148WS would also fit)	D1 to D78
2	22 Ohm resistor	0805W8J0220T5E	R1, R2
1	1 kOhm resistor	0805W8F1001T5E	R5
3	1uF capacitor	CL21F105ZOFNNNE	C3 to C7
5	0.1uF capacitor	0805F104M500NT	C8 to C10
1	16 pins USB type-C SMD connector	TYPE-C16PIN

Please note: Part numbers are just for reference, it's not mandatory to use those, just make sure that capacitors and resistors are form factor 0805 and diodes are SOD-123.
You can use your own crystal of choice as long as it's paired with the correct capacitors.

You also need:

• Two discrete LEDs and Two 0805 resistors for them;
• a set of stabilizers;
• up to eighty switches.

Layouts

The PCB supports split Backspace, Shifts and ANSI Enter key. ISO Enter is also supported.
Bottom row could either be standard or winkeyless (with or without the actual winkey).
LEDs are predisposed in either a dedicated spot or in-switch in the Esc and Caps Lock's pads.




Firmwares

• EasyAVR: Starting from v3.00.01, the TOAD is now officially supported.
• QMK: TOAD is officially supported.

Please note: The TOAD and the XMMX share the same matrix and the former is considered a variant. Make sure you're choosing the correct keymap and layout for your goal.


Plate
I recommend to design your own plate and have it laser cut at your favourite factory.
You can use the universal layout template to design your own.
If you're using swill's builder to draw your plate, please use these custom polygons:

More

Top and bottom supports:
Add polygon - Custom polygon.
shape: [-x/2-10,-y]; [-10,-y]; [x/2-10,-y]; [-x/2-10,y]; [-10,y]; [x/2-10,y]
path: [0,0]; [5,-5]; [15,-5]; [20,0]; [15,5]; [5,5]

Top and bottom supports holes:
Cut polygon - Circle.
diameter: 3
shape: [-x/2,-y-5]; [0,-y-5]; [x/2,-y-5]; [-x/2,y+5]; [0,y+5]; [x/2,y+5]
circle centers: [0,0]

Lateral supports:
Add polygon - Custom polygon.
shape: [-x,-y/2-10]; [-x,y/2-10]; [x,-y/2-10]; [x,y/2-10]
path: [5,5]; [5,15]; [0,20]; [-5,15]; [-5,5]; [0,0]

Lateral supports holes:
Cut polygon - Circle.
diameter: 3
shape: [-x-5,-y/2]; [-x-5,y/2]; [x+5,-y/2]; [x+5,y/2]
circle centers: [0,0]

LED indicators:
Cut polygon - Circle.
diameter: 7
shape: [0,0];[19.05,0]
circle centers: [105,-38]

1u backspace Half-plate:
Cut polygon - custom polygon.
shape: [0,-19.05*2.25]
path: [0,0];[19.05*6.5,0];[19.05*6.5,19.05*1.5];[19.05*6,19.05*1.5];[19.05*6,19.05*2.5];[19.05*5.5,19.05*2.5];[19.05*5.5,19.05*3.5];[19.05*5,19.05*3.5];[19.05*5,19.05*4.5];[-19.05*5.25,19.05*4.5];[-19.05*5.25,19.05*3.5];[-19.05*6,19.05*3.5];[-19.05*6,19.05*1.5];[-19.05*6.5,19.05*1.5];[-19.05*6.5,0];[0,0]

2u backspace Half-plate:
Cut polygon - custom polygon.
shape: [0,-19.05*2.25]
path: [0,0];[19.05*5.5,0];[19.05*5.5,19.05*1.5];[19.05*6,19.05*1.5];[19.05*6,19.05*2.5];[19.05*5.5,19.05*2.5];[19.05*5.5,19.05*3.5];[19.05*5,19.05*3.5];[19.05*5,19.05*4.5];[-19.05*5.25,19.05*4.5];[-19.05*5.25,19.05*3.5];[-19.05*6,19.05*3.5];[-19.05*6,19.05*1.5];[-19.05*6.5,19.05*1.5];[-19.05*6.5,0];[0,0]

If anyone needs help designing the plate, please post your KLE in this thread.


Case
Source code for the case model is available here. This was made with Autodesk Fusion 360 so you can download the .f3d files.
Compiled .step files can be downloaded here. The PDF is for the screw threads as it's required by some factories.
Please be aware that I've not sent the top with blockers to production so it is to be considered untested.

[emenelopee]

Very nice, and nicely done. 

[MajorKoos]

Impressive work.
Thanks for the details on which manufacturers you used.

[LightningXI]

Really impressive work. This is the kind of stuff we need for customs! 

[Sifo]

!!!! still need to build mine and get some parts made for it.

[kurplop]

Impressive work. I really like the direction you went with the Toad. TalkingTree is truly a shining star in the keyboard cosmos.

Thanks for sharing your skills with us.

[TalkingTree]

Thanks everyone for your kind words. It's really a pleasure to be part of this community.

TalkingTree is truly a shining star in the keyboard cosmos.

That's a great comment from someone who's actually a master manufacturer of custom keyboards. Thanks a lot.

[AMongoose]

This is so nice, I should really do an alps build when you release the case design.

[TalkingTree]

Updated the second post with the DIY instructions.

[TalkingTree]

A little bonus for you gentlemen: I made a winkeyless top as well.
Source will be released shortly.

[ygor]

I want one of these so bad. xD

[ojrask]

This is awesome. Need to see if I could make one myself at some point. But really, GB worthy stuff right here.

[TalkingTree]

Need to see if I could make one myself at some point.

If I had, anyone could.

Also added firmwares support to the second post. My thanks to metalliqaz for adding the TOAD and the XMMX' code to the source of his great EasyAVR firmware.

[TalkingTree]

Case source added to the second post.

[TonyD]

impressive, many thanks for sharing it.

[TalkingTree]

impressive, many thanks for sharing it.

Thanks for looking into it.
Hopefully it will be useful to someone.

[ygor]

Did I ever tell you that this board is dope?

[TalkingTree]

Did I ever tell you that this board is dope?

A few hundred times. Thanks you mate. 

[Sifo]

challenge is for me to find a place that'll manufacture it

[TalkingTree]

challenge is for me to find a place that'll manufacture it

Have you asked Ulitemech?

[RealLaugh]

I am signed into autodesk but when I access the page for the case there is no option to download. Do you know another way?

[TalkingTree]

I am signed into autodesk but when I access the page for the case there is no option to download. Do you know another way?

Try reloading the page, I've toggled the download option on again.

[RealLaugh]

Edit: see OP for latest KLE to start building your backplate

[TalkingTree]

I knew something slipped my mind. Thanks for adding the KLE.

[RealLaugh]

I knew something slipped my mind. Thanks for adding the KLE.

No problem, would you mind telling me how you submitted the case files to the fab?

I downloaded the STL and FreeCad can highlight the different components but I cannot separate them (top, plate, bottom, wkl option). That's why I wanted to ask you what file you submitted and if you gave the fab individual files for the top/bottom of the case or if you just simply sent them the fusion project.

Cheers

[TalkingTree]

how you submitted the case files to the fab?

I exported the .stp files from Fusion 360 and emailed them, along with the PDF for the thread sizes, to my contact at the factory.

[RealLaugh]

how you submitted the case files to the fab?

I exported the .stp files from Fusion 360 and emailed them, along with the PDF for the thread sizes, to my contact at the factory.

I don't think I can download the files individually, and also .stp (unless STEP is the same thing?) is not a download option in the Fusion web viewer, am I missing something?

[TalkingTree]

Yes, stp and step are the same thing. I'm not sure about the browser viewer because the entire sharing system on Fusion 360 is a little botched.
Unless you need to modify anything in the case, you can download the compiled step files from my Google Drive account. The link is at the end of the second post.

[RealLaugh]

Yes, stp and step are the same thing. I'm not sure about the browser viewer because the entire sharing system on Fusion 360 is a little botched.
Unless you need to modify anything in the case, you can download the compiled step files from my Google Drive account. The link is at the end of the second post.

Opps I missed that, got them now, thanks!

[TalkingTree]

I'm looking forward to see your TOAD. 

[RealLaugh]

I'm looking forward to see your TOAD. 

Me too, just ordered the PCBs, maybe I can offer the leftovers to someone else if they need some because of the 5 MOQ

[geewizwow]

I'm looking forward to see your TOAD. 

Me too, just ordered the PCBs, maybe I can offer the leftovers to someone else if they need some because of the 5 MOQ

I'm sure we can work something out Have you made any headway with case manufacture ?

[vafan]

How much does the case cost?

[TalkingTree]

How much does the case cost?

I myself paid USD 300,00 shipped, it really depends on where you have it made. This is not a group buy by the way.

[RealLaugh]

I'm looking forward to see your TOAD. 

Me too, just ordered the PCBs, maybe I can offer the leftovers to someone else if they need some because of the 5 MOQ

I'm sure we can work something out Have you made any headway with case manufacture ?

No idea, sent a couple of emails to different email addresses this week but no reply, I am starting to look locally now.

[ygor]

I'd like to purchase one of the PCBs if there are any available. I'd like to eventually collect enough of the parts to build one of these myself so if there are PCBs to be sold, please let a dude know.

[TalkingTree]

I'd like to purchase one of the PCBs if there are any available.

Where are you in the world?

[ygor]

I'd like to purchase one of the PCBs if there are any available.

Where are you in the world?

East Coast of the USA.

[TalkingTree]

I'd like to purchase one of the PCBs if there are any available.

Where are you in the world?

East Coast of the USA.

If nobody can provide you a PCB, I'll see what I can do.

[xondat]

I'm not sure how I haven't commented on this... Suppose I thought I had done already. Anyway.

Great work - the end product is drool worthy.

I loved V1, so it's really nice to see such a great evolution for V2.

I said I wasn't educated on LED pinholes, but I think I'll have to learn some lessons from this execution as it's both clean and functional.

[TalkingTree]

Great work - the end product is drool worthy.

Much obliged good sir.

I loved V1, so it's really nice to see such a great evolution for V2.

I never pictured myself making a custom aluminum case. Your comment was truly the encouragement to follow that route.

I said I wasn't educated on LED pinholes, but I think I'll have to learn some lessons from this execution as it's both clean and functional.

LED indicators is something I really miss on 60% boards and I gotta say that pinholes are the best implementation for them.

[ygor]

Xon Toad case when? :ygorthink:

[RealLaugh]

I made my own plate using your Swills coordinates for the plate mounts and LED holes.

Question I have is, would it be possible to just take the plate file that you shared in the V1 thread? or is that not  compatible with V2?

[TalkingTree]

would it be possible to just take the plate file that you shared in the V1 thread? or is that not  compatible with V2?

No, that wouldn't work without the perimetral supports. V1 was tray mounted while V2 is top mounted.

[RealLaugh]

would it be possible to just take the plate file that you shared in the V1 thread? or is that not  compatible with V2?

No, that wouldn't work without the perimetral supports. V1 was tray mounted while V2 is top mounted.

hmm that's strange because the file that's linked in V1 has those, you can see my swills file on top of the file linked in the V1 thread



I'm not saying your wrong, I just think that you linked the V2 plate file already in the V1 thread

at the end under "V1 Source" you have a pic of the plate with the download files, the plate looks the same as V2

Can you check I am not missing something?

[TalkingTree]

You are indeed correct. After posting the V1, I started working on the V2 and posted some resources in the previous thread. That plate should work as intended. Sorry for the confusion.

[RealLaugh]

You are indeed correct. After posting the V1, I started working on the V2 and posted some resources in the previous thread. That plate should work as intended. Sorry for the confusion.

totally fine! I just needed a confirmation that I could use it to check that what I did in Swill's was correct

thanks for the fast response

[Sifo]

used the swill tool cuz im a noob, anything im missing here? assuming measurements for the cut out area are correct... i actually just eyeballed it but pretty sure i gave myself enough space for switches. not sure about the LEDs but not sure if i'll use them either.

[TalkingTree]

used the swill tool cuz im a noob, anything im missing here? assuming measurements for the cut out area are correct... i actually just eyeballed it but pretty sure i gave myself enough space for switches. not sure about the LEDs but not sure if i'll use them either.

Show Image

That looks fine to me aside for the LED holes that might be insufficient, try adding them to see how the plate looks like. Also, consider my last PM void.
Lastly, if you could share the half-plate cutout, I'll be adding that to the second post as it could be useful to someone else.