Amateur Radio Station K6JEB

So on Saturday, December 1st, 2007, I began assembling my ATS-3B QRP Transceiver. I had decided to start with the six filter boards since they each had three toroids and only one SMT component. I figured I’d save the fun part for last (I have come to really enjoy/prefer SMT) 🙂

This write-up is to record my initial thoughts and show the process for those considering construction of an ATS-3B.

	I use my multimeter to check the surface temperature of my electric skillet. I have found that bringing this warming surface (with the pc board already on the surface) close to 200 degrees Fahrenheit makes the amount of time I need to wave the hot air tool over the components quite short; on the order of maybe ten or twenty seconds.
	I found these Craft Mates bead storage containers at Michael’s Crafts. They keep the contents inside each of the compartments. You needn’t worry about your SMT components getting mixed in these. You can see what’s inside without opening. There’s a spring-loaded latch lock which keep the compartments closed.
	Five of the six band filter boards have an SMT resistor on the side opposite the toroids. I did all five at once time using Cash Olsen’s Hot Air Method. I use the Rival 12″X12″ electric skillet for the warm-up surface. I also use the skillet as my assembly tray because it has nice raised sides.
	This whole process took less than ten minutes. Of course after the solder paste is melted, you should turn off the heat on the warming surface and let it cool down slowly.
	Initially the paste will appear a dull grey but will turn very silver and sometimes give up a tiny puff of smoke.
	After the process is complete and the board is cooled-down, you can pick up the pc board and inspect each connection. I use a combination of my lighted magnifier plus a jeweler’s visor to get a real good look at my work.
	This is how I wind my toroids. There’s a zen to it actually. Using a chopstick in a nice, place the toroid over the tip of the chopstick and the wire, pull the wire taut, and repeat. My hands stay free and without cramps. I can take a break and go grab another beer. 🙂
	Here’s a finished toroid. Can you guess which one?
	When winding toroids, I usually have some music on or something to keep me slightly distracted. This is not a conducive environment for keeping track of windings on a toroid. So I get it really close, and then I scan the toroid my computer and zoom in using any decent graphics program (I use the free Fast Stone image viewer) and count the windings without any pain. I’m usually within one or two windings anyway. Even if you use the pencil+hashmark, it still pays to check your work this way.
	The toroids mounted on a band filter board

The through-hole components were quite easy. I’ve done one board per night in less than an hour each. Two more to go (one tonight and one tomorrow night) and then I begin on the main ATS-3B circuit board.

And as I mentioned last time, our dogs, Honey and Shaggy, had decided to show their superdog wrestling skills right at my feet:

Stay Tuned and 72/73!
Jack, K6JEB