infiniti assembles a 60% Keyboard (FaceW PCB)

[infiniti]

So after a few months of waiting and accumulating parts I'm ready to start assembly.

List of parts / components that I already have:

• Traffic Red (RAL 3020) MKC Aluminum Poker Case from feng's GB -- bought it from naokira
• FaceW PCB from sprit's GB
• Universal Frame/Plate for 60% (silver, soft anodize, full-glare) from GONs KeyboardWorks

• MX-Compatible transparent switch top covers from abostudio

• PCB-mount Cherry Stabilizers from sprit's GB

• Krytox lube kit from mkawa and the GEEKHACKERS.ORG TEMPORARY STORE -- leftover from my Ducky Shine 2 - Mod
• 2x3x4mm Rectangle White Water Clear LEDs from eBay

• 1N4148 through-hole diodes from a local electronics shop

• 0805 SMD resistors from a local electronics shop

• 55g springs from sprit's GB

• silver switch stickers I had cut at a local shop

(picture to follow )

• Cherry MX Clear Switches from MechanicalKeyboards.com

List of parts / components that I am still waiting for:

• PCB-mount Clear Cherry MX Switches from MechanicalKeyboards.com (shipped by my wife's cousin via sea-freight through a freight forwarder -- shipping was free so I cannot complain )
• Switch stickers from MOZ's GB

Edit: Reuploaded pictures to Imgur.  RIP Dropbox Public Folder.

[infiniti]

Edit: Reuploaded pictures to Imgur.  RIP Dropbox Public Folder.

[infiniti]

NOTE: It is a better idea to solder the through-hole diodes to the back/rear of the PCB (i.e. the side that faces the case.

I originally installed the through-hole diodes on the front of the PCB (i.e. the side facing the plate) and discovered that some diodes interfere with the PCB mount stabilizers.  I remedied this by transferring some diodes to the back of the PCB.  Later, I had free time and transferred all the diodes to the rear of the PCB.

28 March 2014 - Soldered on the 1N4148 through-hole diodes

The diodes were individually cut instead of in a roll.  It actually made things easier when I had to bend the legs.


I used a pair of Kelly forceps as a guide in bending the legs.  You need to adjust depending on the size of your forceps and the diode holes on the PCB.

Step 1: Align the first leg


Step 2: Bend the first leg


Step 3: Align the other leg


Step 4: Bend so that the leg is parallel with the first leg


Step 5: Voila!



Here's a guide to what goes where on the PCB:

Note: there are some switches on the PCB where the diode is horizontal rather than vertical.

Done!


Edit: Reuploaded pictures to Imgur.  RIP Dropbox Public Folder.

[infiniti]

6 April 2014 - Soldered on the SMD resistors for the LEDs

I originally bought 0603 diodes since the first store I ordered from didn't have 0805 and it didn't seem that small when I checked the size online prior to ordering: 1.6 mm × 0.8 mm (0.063 in × 0.031 in)

See that on Bob's forehead?  That's a 0603 size SMD.


I decided to be kind on my eyes and looked for another shop that had 0805 size SMD resistors - 2.0 mm × 1.25 mm (0.079 in × 0.049 in).

0603 on the left and 0805 on the right:

________


As this was my first time to solder SMD components, I watched some instructional videos on youtube.

I ended up using the following strategy using:

Step 1: Apply a little solder to one pad

Note: I chose the right hand pad since I hold my iron in my right hand and the tweezers in my left hand.

Step 2: Heat the pad with the solder and lay down the SMD resistor

Note: I heated the pad with the soldering iron in my right hand and then slid in the SMD using tweezers in my left hand.  You can gently use the soldering iron and tweezers to fix the alignment of the SMD.

Step 3: Solder the other pad


Rinse and repeat until done.

Tip: Take a break if you start getting frustrated.  Also, rest your hands every so often if you start trembling and have difficulty aligning the SMD components.
________


Next Step: sticker and lube the switches

Edit: Reuploaded pictures to Imgur.  RIP Dropbox Public Folder.

[MOZ]

Looking good! I usually do it in a batch. First apply solder to the one pad for all the resistors, then place them all on, and then solder the other pad for all the resistors. This allows me not to get frustrated with aligning those tiny part, just do it in one go. Also I always listen to music while soldering, keeps you calm.

[Zeal]

Will be watching this thread! Can't wait for my board to arrive. 

[rowdy]

Are these SMD really intended for hand-soldering?

[MOZ]

It honestly just BGA/FN packages which are not meant for hand soldering, anything which had exposed leads can be hand soldered restricted primarily only be the user skill level.

[infiniti]

Looking good! I usually do it in a batch. First apply solder to the one pad for all the resistors, then place them all on, and then solder the other pad for all the resistors. This allows me not to get frustrated with aligning those tiny part, just do it in one go. Also I always listen to music while soldering, keeps you calm.

That's a good workflow!  This was my first time to do SMDs so I took it slow.

I'll try than when I do the LEDs when the time comes.

________

Will be watching this thread! Can't wait for my board to arrive. 

The next update might be a while...the switches are taking longer than expected to arrive.

I piggy-backed with a sea-freight shipment and didn't pay for shipping so I can't really complain.
________

Are these SMD really intended for hand-soldering?

While you can hand-solder SMD components, they are usually used placed and soldered by machines.  But rework on defective SMD components is still done by hand.

[matt303]

Hats off to you with the SMD soldering  , used to repair the odd SMD board in a previous job, even with a proper rework station and training it was always a pain to do resistors and caps, so small and easy to move when soldering.

[pexon]

Those 0603 sized SMD as sooooo tiny! 

[MOZ]

I actually prefer the SMD stuff as opposed to the TH, one of the reasons being repair, it is such a pain to remove the diodes if you TH solder them and you realize later, that you go the orientation wrong. where as SMD, it is just so much easier.

I don't know if there is a guide out there or if this is the correct method for soldering LEDs, but here is what I do: When installing LEDs, I have noticed that they tend to fall through the hole sicne nothing keeps them locked into their position. What I do is, have the keyboard facing up, place the LEDs, use a hard surface like a cardboard, flip the keyboard and place it on working desk so all the LED pins stay in the wholes, they do fall off a bit, but not out of the holes, I then use a needlenose plier or my hands, pull the LED via one leg (Gently, not to tight and the holes are large enough that both the legs are pulled up evenly even when only pulling using one leg). I then solder the other leg not held, let it cool and move to the other LED. After this is done, I then solder the other leg on all the LEDs, following by trimming of the pins.

Comments on technique?

[jorgenslee]

Hi infiniti,

can you post some other pics of the diode soldered on the pcb, preferably on the esc,1,2,3 area. I saw a diode on one of your pics which I think is in wrong direction. I actually have this issue with sprit's pcb.

[Latin00032]

I thought the SMDs and diodes come pre installed on the board.

[sprit]

Hello!  infiniti ! 
Nice Job!   
You prefer to sold Diodes on the front side of PCB.

 

I thought the SMDs and diodes come pre installed on the board.

1st Round fell sort for the factory SMD presoldering MOQ.   I am doing the SMD soldering now for people.
2nd Round is waiting for that SMD presoldering MOQ. 

[epzy]

I thought the SMDs and diodes come pre installed on the board.

Edit: Sprit answered.

[jdcarpe]

I actually prefer the SMD stuff as opposed to the TH, one of the reasons being repair, it is such a pain to remove the diodes if you TH solder them and you realize later, that you go the orientation wrong. where as SMD, it is just so much easier.

I don't know if there is a guide out there or if this is the correct method for soldering LEDs, but here is what I do: When installing LEDs, I have noticed that they tend to fall through the hole sicne nothing keeps them locked into their position. What I do is, have the keyboard facing up, place the LEDs, use a hard surface like a cardboard, flip the keyboard and place it on working desk so all the LED pins stay in the wholes, they do fall off a bit, but not out of the holes, I then use a needlenose plier or my hands, pull the LED via one leg (Gently, not to tight and the holes are large enough that both the legs are pulled up evenly even when only pulling using one leg). I then solder the other leg not held, let it cool and move to the other LED. After this is done, I then solder the other leg on all the LEDs, following by trimming of the pins.

Comments on technique?

Whatever works for you is fine, I say.

What I do when soldering LEDs is to place a whole row of them in their holes, then use a long strip of masking tape to tape down the whole row of LEDs. Then I turn the PCB over, trim the legs, and solder. It's the same technique I use when soldering through hole diodes.

[MOZ]

Cool,  I should try that on my next board.

[infiniti]

Hats off to you with the SMD soldering  , used to repair the odd SMD board in a previous job, even with a proper rework station and training it was always a pain to do resistors and caps, so small and easy to move when soldering.

Thanks!  I discovered that they're easy to lose too )
________

Those 0603 sized SMD as sooooo tiny! 

Bob stuck one in his nose...he sneezed and it popped out again! )
________

Hi infiniti,

can you post some other pics of the diode soldered on the pcb, preferably on the esc,1,2,3 area. I saw a diode on one of your pics which I think is in wrong direction. I actually have this issue with sprit's pcb.

Here you go buddy:

(Click for biggie)


Note: I soldered the diodes to the front of the PCB and I think I made a boo-boo since the PCB stabilizers won't fit.  Check my reply to sprit's post below for more.
________

Hello!  infiniti ! 
Nice Job!   
You prefer to sold Diodes on the front side of PCB.

Thanks sprit!

I was thinking about your comment...before soldering, I test fit some PCB mount Cherry MX switches and they fit with the diodes in front of the PCB.  BUT I now realize that the diode should go on the back of the PCB since it interferes with the PCB mount stabilizers on Backspace, left shift, and right shift.

Backspace:


Right Shift


Left Shift


I R NOOB.

So...even the through-hole diodes should be installed at the back of the PCB?

________

I actually prefer the SMD stuff as opposed to the TH, one of the reasons being repair, it is such a pain to remove the diodes if you TH solder them and you realize later, that you go the orientation wrong. where as SMD, it is just so much easier.

I don't know if there is a guide out there or if this is the correct method for soldering LEDs, but here is what I do: When installing LEDs, I have noticed that they tend to fall through the hole sicne nothing keeps them locked into their position. What I do is, have the keyboard facing up, place the LEDs, use a hard surface like a cardboard, flip the keyboard and place it on working desk so all the LED pins stay in the wholes, they do fall off a bit, but not out of the holes, I then use a needlenose plier or my hands, pull the LED via one leg (Gently, not to tight and the holes are large enough that both the legs are pulled up evenly even when only pulling using one leg). I then solder the other leg not held, let it cool and move to the other LED. After this is done, I then solder the other leg on all the LEDs, following by trimming of the pins.

Comments on technique?

Whatever works for you is fine, I say.

What I do when soldering LEDs is to place a whole row of them in their holes, then use a long strip of masking tape to tape down the whole row of LEDs. Then I turn the PCB over, trim the legs, and solder. It's the same technique I use when soldering through hole diodes.

That tape method sounds like a good idea.

When I modded my Shine 2, this is what I did for the LEDs:

• fill all the negative LED holes on a row with solder
• push in an LED while I heat up the solder, let it cool, let go of the LED
• do the same for the next switch until I complete the row
• solder up the positive LED holes in that row

Edit: Reuploaded pictures to Imgur.  RIP Dropbox Public Folder.

[riotonthebay]

Infiniti, I had the exact same issue with the stabilizers when I mounted them after soldering all my diodes. Unfortunately I didn't realize it until after most of the switches were soldered as well and had to do some fancy stuff to remove them and flip them to the other side of the board. Worked out fine in the end though

[infiniti]

Infiniti, I had the exact same issue with the stabilizers when I mounted them after soldering all my diodes. Unfortunately I didn't realize it until after most of the switches were soldered as well and had to do some fancy stuff to remove them and flip them to the other side of the board. Worked out fine in the end though

Okie dokie.  I'll do that tomorrow.

Out of curiosity, why did you solder the diodes to front of the PCB (the side facing the switches)?  I think I did so because of the pads.

[riotonthebay]

Infiniti, I had the exact same issue with the stabilizers when I mounted them after soldering all my diodes. Unfortunately I didn't realize it until after most of the switches were soldered as well and had to do some fancy stuff to remove them and flip them to the other side of the board. Worked out fine in the end though

Okie dokie.  I'll do that tomorrow.

Out of curiosity, why did you solder the diodes to front of the PCB (the side facing the switches)?  I think I did so because of the pads.

I don't quite remember. I believe I did it because jdcarpe had done the same for my JD40, which was the only other PCB I had with through-hole diodes and the polarities were on the front of the PCB so it was easier to orient the diodes correctly (this isn't actually the case, so it must have been that first thing – I don't remember ).

[MOZ]

After building my Phantom, I have made it a point never to solder the diodes on the front, for two reasons:
1. Possible interference with stabs
2. If I make a mistake, I can just heat up the two pads and remove the diode using a a needle-nose plier, which is almost impossible if you solder them on the front and then have a plate. To install them pack in, you can solder them like SMD, no problem, which I had to do as I got one diode wrong on my Phantom.

[pichu23]

Looking forward to look at the complete thing
I'm waiting for my pcb from sprit as well. =D

[sprit]

Hello!  infiniti ! 
Nice Job!   
You prefer to sold Diodes on the front side of PCB.

Thanks sprit!

I was thinking about your comment...before soldering, I test fit some PCB mount Cherry MX switches and they fit with the diodes in front of the PCB.  BUT I now realize that the diode should go on the back of the PCB since it interferes with the PCB mount stabilizers on Backspace, left shift, and right shift.

Backspace:

Show Image

Right Shift

Show Image

Left Shift

Show Image

I R NOOB.

So...even the through-hole diodes should be installed at the back of the PCB?

Not always!   But this PCB has quite complicate Diode positions, for ANSI + ISO enter, L-shift, 1x1 Backspace, 1.75x 1x R-shift.... Various Bottom row supports .
When You find problems w Stabilizers,  You can solder those diodes on the backside of the PCB.    ;)

I usually solder all SMD's on the backside as I posted on our GB.   When the Front side is clear, thick 5mm plates can fit.

[infiniti]

Infiniti, I had the exact same issue with the stabilizers when I mounted them after soldering all my diodes. Unfortunately I didn't realize it until after most of the switches were soldered as well and had to do some fancy stuff to remove them and flip them to the other side of the board. Worked out fine in the end though

Okie dokie.  I'll do that tomorrow.

Out of curiosity, why did you solder the diodes to front of the PCB (the side facing the switches)?  I think I did so because of the pads.

I don't quite remember. I believe I did it because jdcarpe had done the same for my JD40, which was the only other PCB I had with through-hole diodes and the polarities were on the front of the PCB so it was easier to orient the diodes correctly (this isn't actually the case, so it must have been that first thing – I don't remember ).

I've been thinking and I soldered the diodes on the front of the PCB because that's how it was on my QFR. )
________

After building my Phantom, I have made it a point never to solder the diodes on the front, for two reasons:
1. Possible interference with stabs
2. If I make a mistake, I can just heat up the two pads and remove the diode using a a needle-nose plier, which is almost impossible if you solder them on the front and then have a plate. To install them pack in, you can solder them like SMD, no problem, which I had to do as I got one diode wrong on my Phantom.

That's true.  I wish I used SMD diodes...it would make everything prettier hehe
________

Looking forward to look at the complete thing
I'm waiting for my pcb from sprit as well. =D

It's worth the wait!  I can't wait to get this complete and start typing on it!
________

Hello!  infiniti ! 
Nice Job!   
You prefer to sold Diodes on the front side of PCB.

Thanks sprit!

I was thinking about your comment...before soldering, I test fit some PCB mount Cherry MX switches and they fit with the diodes in front of the PCB.  BUT I now realize that the diode should go on the back of the PCB since it interferes with the PCB mount stabilizers on Backspace, left shift, and right shift.

Backspace:

Show Image

Right Shift

Show Image

Left Shift

Show Image

I R NOOB.

So...even the through-hole diodes should be installed at the back of the PCB?

Not always!   But this PCB has quite complicate Diode positions, for ANSI + ISO enter, L-shift, 1x1 Backspace, 1.75x 1x R-shift.... Various Bottom row supports .
When You find problems w Stabilizers,  You can solder those diodes on the backside of the PCB.    ;)

I usually solder all SMD's on the backside as I posted on our GB.   When the Front side is clear, thick 5mm plates can fit.

I used through-hole diodes since I expected SMDs to be a pain.  After soldering the SMD resistors, it's actually easier...no bending and trimming legs.  I'll go with SMD diodes next time but only in size 0805 :)) 0603 is waaay too small. ^-^

[infiniti]

7 April 2014 - Moved the diodes that interfered with the PCB-mount stabilizers to the back of the PCB

I installed the through-hole diodes on the front of the PCB (i.e. the side facing the plate and depending on your layout, there may be some diodes that will interfere with the PCB mount stabilizers.  This can easily be remedied by installing the diodes on the back of the PCB.

Backspace:


Left Shift:


FN (originally thought it was for the Right Shift):


TA-DAH!


Edit: Reuploaded pictures to Imgur.  RIP Dropbox Public Folder.

[mashby]

Thanks for posting this. I'm really enjoying watching your progress.

Great photos too by the way.

[riotonthebay]

Yep, this should be a huge help for everyone about to assemble these . I wish I had this resource before I assembled mine.

[Michael]

I think I need to have you do my 360 Corsa PCB

[Dreamre]

I love your build threads, looking forwards towards your final build .

[HPE1000]

I don't think I actually posted in this thread yet, but I am watching it for sure. Good luck, I cannot wait to start building mine, it will be my first keyboard I have built from the ground up

[rowdy]

Great pictures, even if they are a bit Bob-less

[infiniti]

Thanks for posting this. I'm really enjoying watching your progress.

Great photos too by the way.

Thanks!  I enjoy putting this together for community reference.

== = == = == = ==

Yep, this should be a huge help for everyone about to assemble these . I wish I had this resource before I assembled mine.

Exactly!  The stabs and the through-hole diodes is something you'll only learn by doing.

== = == = == = ==

I think I need to have you do my 360 Corsa PCB

I'd gladly trade services for BroBots or ZomBros!  

P.S. Don't worry I will pack very well...much like this.

== = == = == = ==

I love your build threads, looking forwards towards your final build .

Thanks!  The final build...depends on a major consideration...WHAT CAPS DO I PUT ON IT???

== = == = == = ==

I don't think I actually posted in this thread yet, but I am watching it for sure. Good luck, I cannot wait to start building mine, it will be my first keyboard I have built from the ground up

This is my first too!  *fist bump*

== = == = == = ==

Great pictures, even if they are a bit Bob-less

Thanks!  Bob just got back from vacation...he tried working on his tan but only his red eye got more red )

[infiniti]

Struck gold!



Edit: Reuploaded pictures to Imgur.  RIP Dropbox Public Folder.

[infiniti]

24 April 2014 - Have Time, Will Solder: moved all the diodes to the rear of the PCB

'still waiting for the switches...should arrive any day now (or so I've been told).

After seeing YUIOP's NerD TKL Build, OCD kicked in and I couldn't live with some diodes in front and some at the back.

I had time so I desoldered all the diodes and resoldered them to the rear of the PCB.

Voilà!

Front (facing the plate and switches):


Rear:


Back to waiting on switches...

Edit: Reuploaded pictures to Imgur.  RIP Dropbox Public Folder.

[Photekq]

Great log so far man!

[YongJK]

Just don't solder diodes at front face, it will be pain in the ass in case diodes decided to fail.

[infiniti]

Great log so far man!

Thanks!

Just don't solder diodes at front face, it will be pain in the ass in case diodes decided to fail.

Yeah...kinda realized that and resoldered them to the back of the PCB.

I should note that somewhere in an earlier post so someone else doesn't make the same mistake.

[HPE1000]

Going to be assembling mine Monday or Tuesday, I am excited

I'm doing diode and resistor soldering, should be fun.

[infiniti]

Going to be assembling mine Monday or Tuesday, I am excited

I'm doing diode and resistor soldering, should be fun.

Nice!  It is fun...so fun I did it twice! )

REMEMBER: It is a better idea to solder the diodes to the back of the PCB.

P.S. I had stickers cut yesterday so I'm just still waiting on the switches...

[sprit]

Nice!  It is fun...so fun I did it twice! )

REMEMBER: It is a better idea to solder the diodes to the back of the PCB.

P.S. I had stickers cut yesterday so I'm just still waiting on the switches...

I am going to ship more PCBs this week,  hope many enjoy assembling.

[infiniti]

Bob finally got the clear switches!

OG Cherry Switch Boxes!


Inspection:


Time to disassemble.  Lubrication..hehe lubrication...starts in the morning!

Edit: Done disassembling. It took me a while since I was watching 24...beep...boop...beep...boop...

Edit2: Reuploaded pictures to Imgur.  RIP Dropbox Public Folder.

[mashby]

Very cool that you got the boxes that they come in as well. If you don't mind me asking, who did you order them from?

[SaySo]

.

[mashby]

Eh eh the answer is in the op

• Cherry MX Clear Switches from MechanicalKeyboards.com

Show Image

Show Image

Doh! Thanks SaySo.  )

[mashby]

grrr. double post.

[infiniti]

NOTE: Mount the stabilizers to the PCB before mounting the switches to the plate and PCB.

'got distracted by other things so I just finished lubing and mounting the switches.  I'll solder the switches and LEDs tomorrow



Edit: Reuploaded pictures to Imgur.  RIP Dropbox Public Folder.

[mashby]

Looking good!

What made you choose to use an MX-Blue for your CapsLock / Control?

[infiniti]

Looking good!

What made you choose to use an MX-Blue for your CapsLock / Control?

Thanks!  It's a blue stem with a clear spring. That way it's a little difficult to accidentally toggle the caps lock. The click also let's me know it's been pressed.