Author Topic: Shortcake - a Dell AT101W mod  (Read 8709 times)

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Offline geniekid

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Shortcake - a Dell AT101W mod
« on: Tue, 19 August 2014, 22:20:24 »
I want to show you guys the end result of a small project I recently completed, named Shortcake. 

75118-0

It's a Dell AT101W I found at work (1 of 2) that my boss allowed me to take.  The base keyboard is a 104 key keyboard with complicated black Alps (Alps SKCM Black) and a PS/2 interface.  I did the following:
  • Cleaned all the parts.
  • Desoldered the switches.
  • Painted the plate red.
  • Soldered on Matias tactile switches.
  • Installed a Teensy with Soarer's converter to make it programmable with a USB interface.
  • Replaced green LEDs with red ones.

The biggest challenge I encountered was desoldering.  I was too preoccupied during the process to take pictures, but the original switches were soldered with the legs bent at a 90 degree angle.  I used my soldapullt to remove most of the solder and then used some pliers to bend the legs straight.  For a few switches I had to heat the joint while bending the legs straight.  Three of the pads ended up partially lifted, but nothing over 50% - the switches all work fine.

The second biggest challenge I encountered was painting the plate, although this was mostly due to my own failures.  If I did this again, I would be sure to let the paint dry fully before turning it over to paint the other side.  I would minimize the surface area in contact with anything else and mask that area if it was already painted.  Also I would not have saran wrap underneath it as it melted into the paint while I was doing the clear coat.  I had to sand it down and repaint it because of my mistakes.  I'm surprised it ended up looking as good as it did (picture below).

I have to say that Soarer's converter is quite amazing.  I had to read through a lot of documentation and forum posts to understand exactly what to do.  In retrospect I probably should've just asked for help, but after half a day I was able to successfully program my usual layout onto it.

Deconstructed.
75120-1

Additional parts for modding.
75122-2

PCB, desoldered.
75124-3

A painted plate.  This is the final result after I had to sand it and repaint it due to mistakes (see above).
75126-4

Installing the converter.  I soldered header pins to the Teensy and used hookup wire with connector housing to connect the keyboard to the Teensy.
75128-5

Strawberry jam plate under the creamy key caps.  Yum!
75130-6

Red LEDs to match!
79193-7

I'd like to get a little more red on the keyboard via the key caps but it is exceedingly difficult to find Alps caps, especially for an ANSI 125 layout.  I'm hoping when Matias starts selling his key caps I will have more options :)

UPDATE (August 21st 2014)
One thing I've noticed is that the AT101W doesn't support full NKRO (or even full 3KRO) despite the native PS/2 interface.  In particular, LAlt+RAlt+].  Specifics of my layout aside, I find that I have to use the dedicated navigation keys in some cases to access certain shortcuts while coding instead of through my usual navigation function layer. 

UPDATE (Oct 8th 2014)
I replaced the green LEDs with red ones to match.
« Last Edit: Wed, 08 October 2014, 08:54:00 by geniekid »

Offline SpAmRaY

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Re: Shortcake - a Dell AT101W mod
« Reply #1 on: Tue, 19 August 2014, 22:40:18 »
I came in here expecting to find an AT101W turned into a TKL :P

Nice job by the way even if its not a TKL. :D

Offline fohat.digs

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Re: Shortcake - a Dell AT101W mod
« Reply #2 on: Wed, 20 August 2014, 10:25:22 »
I came in here expecting to find an AT101W turned into a TKL

Me, too. That was Grimey's project, wasn't it?

Why the whining about painting the plate? I absolutely do that with every Alps board I rehab or mod. The only reason it takes 24 hours is because that is how long it takes good paint to dry.

I applaud your choice of the AT101W as a great solid chassis to work from.
Citizens United violates the essence of what made America a great country in its political system. Now it’s just an oligarchy, with unlimited political bribery being the essence of getting the nominations for president or to elect the president.
So now we’ve just seen a complete subversion of our political system as a payoff to major contributors, who want and expect and sometimes get favors for themselves after the election’s over.”
- Jimmy Carter 2015

Offline SpAmRaY

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Re: Shortcake - a Dell AT101W mod
« Reply #3 on: Wed, 20 August 2014, 10:33:11 »
Me, too. That was Grimey's project, wasn't it?

His was a little more extreme :D

http://geekhack.org/index.php?topic=37739.0

Offline geniekid

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Re: Shortcake - a Dell AT101W mod
« Reply #4 on: Wed, 20 August 2014, 12:42:53 »
Thank you Spamray and fohat.digs for the compliments.


Me, too. That was Grimey's project, wasn't it?

His was a little more extreme :D

http://geekhack.org/index.php?topic=37739.0
Wow...that guy has more tools and courage than I have.


Why the whining about painting the plate? I absolutely do that with every Alps board I rehab or mod. The only reason it takes 24 hours is because that is how long it takes good paint to dry.
It was a huge pain in the ass because of all the mistakes I made as an unexperienced spray painter.  I was too impatient and turned the plate over before it was fully dry to paint the opposite side.  As a result, some of the cardboard stuck on to the still wet side.  I sanded some of it off and repainted.  After a couple of days I decided to apply a clear coat, but this time I had it resting on some saran wrap which melted off and stuck to the plate.  So I had to do a much heavier round of sanding all over and then repainting and then reapplying the clear coat.  The switches ended up being a very tight fit and in some cases actually peeled off the paint on the inside of the switch holes.

If I had to do it again I would be much more patient and wait for each side to dry completely.  I would try to minimize the surface area of the plate in contact with anything else and mask the contact areas with painter's tape. 

That said, I think it turned out surprisingly good considering all the mistakes I made.  With the cover and caps on I think it's very difficult detect my painting ineptitude at all.  Certainly I will not be making these mistakes again!  I'm sure I'll discover a whole new set of mistakes to make :)). 

Offline fohat.digs

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Re: Shortcake - a Dell AT101W mod
« Reply #5 on: Wed, 20 August 2014, 12:52:01 »
If I had to do it again I would be much more patient and wait for each side to dry completely.

Always follow paint can instructions to the letter.

I advocate many very thin coats. Usually you can do 3-4 passes in something less than an hour, then let it cure for 24.

No need for a clear coat if it will not be getting touched. Yes, you can restrict the holes, keep it thin.

Empty egg cartons make excellent spray paint stands.

There was another project turning an AT101 into a TKL, Grimey's project is amazing but I was thinking of something else. I think this is it:

http://geekhack.org/index.php?topic=9542.150

but the pictures seem to be gone.

« Last Edit: Wed, 20 August 2014, 13:01:22 by fohat.digs »
Citizens United violates the essence of what made America a great country in its political system. Now it’s just an oligarchy, with unlimited political bribery being the essence of getting the nominations for president or to elect the president.
So now we’ve just seen a complete subversion of our political system as a payoff to major contributors, who want and expect and sometimes get favors for themselves after the election’s over.”
- Jimmy Carter 2015

Offline CPTBadAss

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Re: Shortcake - a Dell AT101W mod
« Reply #6 on: Fri, 22 August 2014, 15:45:11 »
Geniekid, what didn't you like about painting the plate?

Offline geniekid

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Re: Shortcake - a Dell AT101W mod
« Reply #7 on: Fri, 22 August 2014, 15:54:47 »
Geniekid, what didn't you like about painting the plate?

See two posts above :)

tl;dr - Nothing really.  I actually was enjoying it until all my screw ups - I'm still amazed it turned out as well as it did.  Anyway, I'll do better next time.  I will also edit the OP.

Offline jacobolus

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Re: Shortcake - a Dell AT101W mod
« Reply #8 on: Fri, 22 August 2014, 15:56:49 »
Geniekid, what didn't you like about painting the plate?
Did you miss his explanation here? http://geekhack.org/index.php?topic=61967.msg1443275#msg1443275

Offline CPTBadAss

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Re: Shortcake - a Dell AT101W mod
« Reply #9 on: Fri, 22 August 2014, 16:03:53 »
It's very apparent I can't read, my bad

Offline geniekid

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Re: Shortcake - a Dell AT101W mod
« Reply #10 on: Fri, 22 August 2014, 16:05:09 »
I've edited to the OP to explain a little more about my painting errors and what I learned from them.  I also removed the assertion that I would never paint a plate again :)

Offline fohat.digs

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Re: Shortcake - a Dell AT101W mod
« Reply #11 on: Fri, 22 August 2014, 17:21:39 »
It's very apparent I can't read, my bad

TL;DR applies after 140 characters

Somebody should find those pictures for the AT101 TKL
Citizens United violates the essence of what made America a great country in its political system. Now it’s just an oligarchy, with unlimited political bribery being the essence of getting the nominations for president or to elect the president.
So now we’ve just seen a complete subversion of our political system as a payoff to major contributors, who want and expect and sometimes get favors for themselves after the election’s over.”
- Jimmy Carter 2015

Offline Igthorn

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Re: Shortcake - a Dell AT101W mod
« Reply #12 on: Fri, 22 August 2014, 18:14:35 »