It is important to carefully bend capacitor leads to fit easily into holes. If you force leads not formed, you may break lead off capacitor body. Because of various manufacturers, the lead spacing may vary greatly. The picture below shows leads of a preformed capacitor (left) from manufacturer, and leads that will be bent by you (right).
Hint: If you don't have access to a good magnifying glass and have a smartphone, use your smartphone camera to take a picture of the small printing and zoom in to magnify just like the picture above and below.
When the capacitor is mounted it should look like this:
D1 - 1SV149 orientation. Must be installed as shown below.
R24 - 500 ohm potentiometer lead spacing
Some pots that come with the kits may not have the lead spacing that the board is laid out for. You will need to bend the wiper pin (right pin in picture) slightly with needle nose pliers as shown and straighten the other two leads and bend the two left pins slightly towards the center.
Insert pot on board and make sure its straight like the picture below and solder.
Diode D11 and D12 (if used) are identified as follows:
D11 (1N5236 7.5V zener) has a silver body as of this run of parts.
Caution must be noted on the 7.5 volt and 33 volt zeners. They could be clear glass type like the 1N4148 or they may have a silver coating on the case. Some batches have case coatings reversed. In any case, use a magnifying glass to verify the correct numbers. 1N5236 7.5 V, 1N5257 33V.
D12 (1N5257 33V zener) has a glass body and looks like a 1N4148. Do not mix them up!
D12 comes in a bag with D11 and separate from other diodes.
Closeup view of RG174 soldered to board.
As of this board run you may have to remove a few strands of braid to get it to insert into board.
Rear panel power connector wiring.
Center pin is +12 volts!
Some components will have tape holding the leads together. These parts are normally used in automated insertion equipment. The leads are long enough that you can just cut the leads close to the tape rather than pulling tape off. Some of the adhesive may remain on lead ends and inhibit a good solder joint if adhesive gets stuck in through hole.
You must decide what type of earphones or headphones you will use. The most common is a stereo type MP3 earbuds or Walkman type earphones. Stereo plugs will have a tip, ring, and sleeve or 3-circuit plug. If this is your case just tie the tip and ring together going to J3 Pin 2. Just remember that if you plug a mono 2-circuit plug into this jack it will short the output to ground.
For the key jack tie the ground to chassis and the tip to the key circuit
Your kit includes pins for the modular connector housing should you decide not to wire directly board.
If you decide to use header connectors instead of wiring
directly to board, follow the instructions below.
Strip wires as shown above. If you are fortunate to have a good crimper, set the pin as shown.
The above shows a good crimp.
I you do not have a crimper you can carefully solder wire to pin. Strip wire and place in pin as shown above.
Carefully fold portion of pin around stripped wire.
Carefully dab solder over the crimp. Too much heat will cause solder flow throughout the pin rendering it useless.
Using needlenose carefully roll the part of the pin around insulation. Be sure to roll it tight otherwise it will not fit into the housing.
Push pinned wire into housing with solder side up and holes in housing up. They should snap in.
If you need to remove a wire you can insert a sharp blade to release the latch on top of housing and pull wire out.
Using a knife or Xacto blade carefully scrape enamel insulation about a quarter inch from the toroid body.
No need to scrape the whole length.
You can leave the wire leads long to ease inserting them into holes.