Wires & Pliers

Kit building: Do it yourself!

Matt Minney, N8PGI

Amateur Radio operators have had a reputation for building their own equipment since the beginning of the hobby. In the early days, building your own gear was a virtual necessity. Many people could not afford manufactured gear so one had to be creative. Today, it's not a necessity to build equipment, but that does not mean that the days of building kits or working on your own equipment are over. Quite the opposite; there are several reasons to start building a kit.

One major reason to get involved in kit building is to learn more about radio. As the kit builder works, he picks up information on how electronic equipment is assembled and learns electronic theory. Depending on the kit that is selected, the final product itself may be the best reason to build the kit.

It's possible to add a station accessory, neat household gizmo,or even another transceiver to your Ham station. There is also the feeling of accomplishment that this device was built with your hands and your ability.

Many people would look at the previous reasons and declare that they could not possibly assemble a kit. The usual concerns are that building a kit is too hard, one would have to be an engineer to understand all the modern technology, and they are too expensive. If the kit builder spends time choosing a good "first project" when starting out, kit building will not be too hard and with good instructions, can be quite simple. The idea is to gradually move to more challenging projects as one becomes ready for them.

The second concern will be taken care of along with the first in most cases. A kit builder will learn the symbols and terms as he goes along. If the kit instructions do not include a listing of electronic symbols, acquiring an old copy of the ARRL Handbook would be a good idea. Having some type of reference material would also be a good long term step for building your station as well.

The third major concern is that the kits are too expensive. The best way to refute this is to look at kit prices in a Ham magazine. Most are cheaper than their factory made cousins, but this fact will obviously vary.

Once an amateur has decided to build a kit, a few tools need to be acquired. These basic tools are also useful in fundamental repair and replacing of coax connectors.

The first basic tool is a soldering iron. An iron that uses 15 to 25 watts will suffice for most jobs. Along with the iron, a roll of rosin core solder is a must for most projects. Some type of multimeter is the basic piece of test equipment, which will be needed for most jobs. At this point, purchasing expensive test equipment is not necessary and not recommended.

Another necessary tool is some type of small wire cutters. A wirestripper is a nice addition, but this is not essential if a pocket knife is handy. Another necessity is a pair of needlenose pliers. These pliers are very handy and will prove to be invaluable on every project. Other things around the house you will need include electrical tape, screwdrivers, and a jar of spare nuts and bolts. If these items are not in your possession, a trip to the local electronics store will help to complete the list. A local hardware store might also have these items.

A final consideration on materials required to build a kit, is where to do the construction. A suitable place to build a kit should be a flat solid surface that is well lit. An area without distractions will also help make the experience more enjoyable, while preventing mistakes. When selecting your construction site, remember that one should have proper ventilation while using the soldering iron to prevent the inhalation of solder vapors.

Generally, a project will not need power until complete, but a 12 volt DC supply is a good addition to your construction bench. Often an Amateur Radio operator already has a 12VDC power supply attached to a 2-meter radio, which could be pressed into service if needed.

Once the preparations are made, it is time do decide on a first kit to build. It's a good idea to choose a kit that is not extremely difficult to construct, to allow for some practice before engaging in a larger project choice. Catalogs are available from the major kit producers for your first project. Companies such as T-Kit, Ramsey, or others that advertise in some of the electronics hobby magazines would be excellent choices for your first project.Take some time and choose carefully, to avoid making your first kit experience a bad one. A receiver of some type has been a traditional first kit in many cases, but the builder is the best judge of what that kit should be.

Once the new kit has arrived, it's now time to get to work. Check the parts list to make sure that all the parts listed are indeed present. This step should not be overlooked. If something is missing, which can and will happen, it is best to find out early and call to obtain the lost part.

After the inventory is taken, browse through the instructions or manual that came with the kit. The time spent learning about the upcoming steps will prevent mistakes later. Note any changes to the included instructions made at the last minute. A final check of the list of required tools should be the same as the list discussed earlier, but a quick check may save time later.

The construction is a matter of following the instruction manual, but there are a few things to keep in mind during this phase as well; the foremost of these is not to rush. It is a great temptation to rush through the steps to see a finished product, but skipping even one step can prevent the kit from working. The kit may even be destroyed, so care must be taken.

Another consideration is the method of soldering. Soldering is an acquired art, so do not be disappointed if the technique is not perfect on the first try. With practice anyone will improve. The main things that can be done are watching for solder bridges between two parts of a circuit board, and making a good electrical connection.

A solder bridge can be found by periodically checking for solder that runs across the board's traces, or solder anywhere not on your diagrams. If this occurs, carefully reheat the connection that caused the bridge. If the solder doesn't move then, take a flat screwdriver or knife and carefully separate the traces.

To make a good electrical connection, make sure the iron will easily melt the solder. A dull connection may be another sign of a poor connection. Reheat the connection if it is suspected to not be conducting. Solder problems are a common reason for a kit not working properly.

As the kit is being completed, some instruction manuals will contain periodic checks to see if the most recently completed steps are working correctly. This and other tests are usually optional, but can point out a mistake in construction before the problem becomes difficult to correct. If a problem does arise, go back through the steps of the last section and double check your work. A second check is a good rule even when everything works properly.

Depending upon the kit purchased, there may or may not be a case provided with the kit. If there is no case, there are two options. One is to purchase a case from the kit manufacturer or an electronics store, or buy some materials at the hardware store and make your own. The best idea for the first kit is to buy a kit with the case included.

At the end of the construction steps, a final check should be completed before testing out the new equipment. Then the new kit is complete and ready for whatever use for which it was intended.

After finishing the first kit, it is very possible that kit building and electronics in general will become the kit builder's new hobby. There are several directions in which a new builder can go. The obvious and best is to continue to build more kits. This will allow the builder to continue to obtain new skills and new knowledge as the kits become more complex. More opportunities will become available later on.

One of these would be to repair and refurbish old receivers and other "boat anchors," which is a general term for old tube type radios. Working on this type of equipment would require a few more tools, specifically a tube-tester, but rebuilding old equipment can be just as much fun as building new kits.

Another option is to begin building things yourself. This does not need to be as difficult as it might appear. Start with a simple construction article from an Amateur Radio magazine and slowly build toward more complex plans, perhaps even modifications to your own radios. With practice, the repair of anything pertaining to the Ham station will become possible. At the least, the experience gained from kit building will be helpful in identification of a problem when it comes. With more practice, a novice kit builder can become very proficient in electronics.

The basic introduction to building a kit in this article cannot fully explain the feeling of satisfaction associated with the ability to make equipment or complete projects related to Amateur Radio. Many people say that kit building is obsolete or unnecessary, but the best way to really experience this part of our hobby is to start a project.

The information here is intended to introduce you to the basic requirements and pass along basic hints related to building a kit. In many ways, constructing a kit not only builds equipment, but also furthers the builder's ability and improves the Ham operator's experience and knowledge of his hobby.

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