Full developement credit/creators(C.P.U.(2008) , Robert Petružela (Bob!k) & Radek Šterba (Raster)) is at:SDRIVE. Please refer there for their updates.
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First, you need a circuit board. I made a pcb. Do a continuity check of all traces before soldering anything. My pics are HERE. You can also hand wire. Read through these instructions several times. If you don't understand something, ask questions(chat). I ultimately ended up using the same case as I do for my Spider. It has plenty of room for parts to spread making soldering easier with a handmade board.  The case this is fitted for is a Pactec #HP. Mouser#616-60616-510-000(black) #616-61989-510-039(beige) Space board from bottom of case. I use 1/4" rubber feet. Do not put on to close to board edges. |
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Marking for three slots on case with my pcb:(rev...dec2010) * PCB:On case bottom-put blue tape in those places-sdcard, sio jack, dip switch, wrapping it inside to outside, smoothing down. On case top, you will need a piece for SIO top. See my pcb layout for reference. Casepics: Sd notch-Daughterboard Mount!, Dip notch, SIO notch  * Insert the pcb into the bottom of the case, keep it centered(closer on sd socket side is o.k.). Use a fine marker to draw a line where the level of the board is to the sd card and SIO jack pieces. * SD Card/daughter board:Solder card to daughter board, solder header pins on card side(see info further down). Since it tends to bend up when installed, put a shim under the front and tape down. Install it(don't solder to main board). and draw a line across the top on the case inside. Mark 1/16 inch down, this is where the top of the hole will be. Mark 1/8 inch down from here...this is the bottom of the hole. Transfer these locations to the outside of the case. Drill 1/8 inch holes inside the lines at the left and right ends, connect these holes for lines to cut using a jewelers saw. Remove tape. File to the correct size. Depending on location, the top may need the flange cut. If you are installing the sd card socket on the bottom of the board...there may not be enough room for this. You may need to stack another set of small feet on the four on the board first. Mark 1/16 inch below line, mark another 1/8 below this, mark sides of socket, follow as above. * Dip Switch:Insert switch to locate sides, transfer to outside. Mark line 1/8 to 3/16 inch from top of case edge. Fine saw the sides of the slot. Score carefully with a razor blade across the bottom. Remove tape. Use a straight edge. Slowly snap out with pliers. Clean with file to desired size. The top may need the flange cut for sdcard and dip switch. The SIO jack will need about 1/4 inch more cut out of the top. With case halves together, use jack to mark height, cut out same as before. * SIO Jack:This one is a little harder since it sticks out. Insert into pcb. Lay in case bottom at angle. Mark sides on case edge. Transfer marks and pcb level to outside. Fine saw the sides of the slot. Score carefully with a razor blade across the bottom. Use a straight edge. Slowly snap out with pliers. Clean with file to desired size. Remove pcb, put case top on, mark sides, measure sio jack height, subtract bottom slot, measure up on case top, makr, cut out as above. Allow for slant and case flange-case will not snug up completely with blue tape on it. Always file a little, check location, repeat. Its easy to go to far when scoring and sawing. |
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At this point, you are ready to assemble the board. If you haven't done it already, use meter or battery/led/wires to check the continuity of all traces. Solder repair any that fail. The boards I send out has this done. Switch Prep:What you do depends on where you plan to mount the buttons. The large buttons need pin extensions to make them long enough to stick thru the case top. Prop up the pcb to get clearance. Place pins in holes lining them up. Flat side of button to left or right. Solder button pins to ext pins. Check. Re do until straight and parallel. OR, take a piece of wood, push one set of switch pins into it to mark, drill out 1 inch deep. This becomes the template.  Soldered.  For Show ONLY at this point! |
Install Jumpers: You put in the five that are blue in the parts placement diagram. I used 24ga solid wire. The green one is optional. It helps with ground, but secures the sd daughter board too. See SDsocket below. |
Install Resistors, capacitors(one is polarized), Diode(note dir of band, square pad gets bar end).  |
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Install IC socket(note pin 1/notch dir), voltage regulator(note dir of flat), Xtal, dip switch, SDsocket. Buttons, LEDS, SIO jack are next. |
Install SIO jack. Don't forget the screws, nuts on top.  SD Card board:Pretin and clean the sd socket pads all around. Carefully align the socket to the pads. Tack solder each end. Check, realign as needed. Solder all of the pins at the connector, the switch pin at the front, and the four corners. Install header strip long pins thru foil side, flush with plain side. Solder pins evenly, move spacer as close to pcb as it will go. If no, using the daughter pcb, mount the SD socket to the underside of the pcb. (17mar09)Here is a picture showing where to solder the SDsocket on either the main boared or the daughter board. Do not skip the stray pin on the side, else it won't know a card is inserted.(Thx Steve).  Also NOTE X:Once I drilled out the sd connector, I found a weak ground connection on the foil side. This can be fixed by placing a small solder blob at that hole.  . If you are going to mount the SDsocket on the main board foil side or you just want to reinforce the connector, two small holes can be drilled and a jumper placed on top here.  .
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Do final filing of case holes as needed. No Binding. Clean up edges. Install Switches.  Install switches, flat to right, till pins bottom out. Solder a couple of pins, adjust till straight. (change here)Do not solder other two pins until case top is done. This will make aligning switches to holes much easier. Repeat for other three, use heavy cutters to cut excess for all pins sticking out from bottom. Install LEDs.  Flat goes inwards.A couple of pieces of 2.5cm long straw(slit lengthwise) makes great spacers. Do outside 2 leds, then move inwards. OR Using card stock, cut a strip about 3" long, by 28 mm, score in middle, then fold. I have found this easier than the straws. Carefully pull out when done, if desired. This shows possible way to install LEDs. Straight up in my project, out out to side, flat, or twisted.  Once all of the parts are in, trim any excess lead length from the foil side of the board. An alternate foil side parts placement is here. Use a spacer to make room to solder.  . An alternate parts placement is to use my new LED/Switch board I make for use with the SDrive Bay Mount version. NOW is the time to check for solder bridges and cold joints on the foil side. |
Use the template or the label to locate the holes in the top for the buttons and LEDs. Start with smaller holes, file larger in the direction needed to let the components slide through easily. Should match the label if everything installed straight. Make adjustments to the case or the component as needed.  Solder other switch pins at this time. Once done, use static precautions to insert atmega chip into socket, notch towards LEDs. Make sure all of the pins are in the socket contacts. Cut out top label as needed(at least 6 LED holes and 4 button holes). Test to fit, trim outside and holes as needed first(I used a 1/4" hole punch and curved cuticle scissors). Then peel backing and apply to clean top recess.  Card inserted, system drive(sdrive.atr) found.DONE! Another section describes my experiences in programming the atmega chip, and in actually using the sdrive. Once everything works, screw case together. P.S. What are the black rubber feet really for? Besides helping to center the SIO jack in the case, they raise the pcb up enough for the SIO jack mounting screw heads. Required to keep the jack from coming loose. |
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