Hours 0:44:00 Total Build Time: 37:45:00 Nov 21, 2011
Spent the evening installing ICs on the RF board. Ran into another set of NE602 ICs (Double balance Mixer/Oscillators) that were replaced by SA612AN chips. The replacement chips were not mentioned in the manual or Errata sheet for the manual. This was not a problem since the replacement could be confirmed by searching the internet.
One of the steps included mounting the MC1350 Surface Mount IF amplifier IC. The Surface Mount IC came already soldered to the PC board as shown. Connector pins were supplied to mount the Surface mount PC board to the main RF board.
Hours 0:45:00 Total Build Time: 34:49:00 Nov 15, 2011
It is slow going installing the capacitors. I think it is progressing slow because first I have to sift through all the capacitors looking for the one I need. Next the capacitor is stuffed into the board in the correct position, and finally it is soldered. I was able to install 10 capacitors tonight.
Capacitors installed on the RF board
Sorted capacitors
There are 57 remaining capacitors to install before I can move on to the next step.... This could take a while.
Hours 2:24:00 Total Build Time: 34:04:00 Nov 14, 2011
Well, it had to be done some time.... I came to the step in the construction of the RF board where the capacitors are loaded on the board and soldered. The first thing that I realized was it was going to take forever sorting through the capacitors trying to find them. I think I remember the step right before the installation of the first capacitor saying that all the capacitors should be sorted but who wants to do that..... :)
The capacitors are not like the resistors. The resistors come loaded on a tape in the order that they are used on the board. Its a matter of verifying the color code, cutting the resistor off of the strip, and loading and soldering onto the board.
The capacitors came all mixed together. The only capacitors that were not mixed together were the .01 uf and .001 uf .
Lots of really small capacitors!
Yes I spent 2 hours and 24 minutes tonight just sorting and taping the capacitors together. First I was going to put the capacitors in zip loc bags. After thinking about that I was going to use envelops. Finally I decided that scotch tape would work and I would write the id number used in the manual on the tape.
Capacitors taped together
I am finally finished sorting them. The biggest problem was with the small blue colored capacitors. The ID number on them was in silver. I had a hard time trying to identify them even under the lighted magnifying glass. I would have to shade the capacitor just right to see the numbers on them.
Hours 3:03:00 Total Build Time: 31:40:00 Nov 13, 2011
Started working on page 50 of the manual today. The first item to build was the PLL (phased lock loop) upgrade. The upgrade includes a thermistor that will keep the frequency more stable on the K2.
PLL Upgrade Kit
The PLL upgrade kit consisted of some wire, several resistors, a thermistor, and the circuit board.
Parts for the PLL Upgrade kit
Man these parts are small. Most of the components of the PLL upgrade kit were 1/8 watt resistors.
View of the PLL upgrade kit
The PLL upgrade kit replaces on of the resistor packs RP3 on the RF board. Wires were soldered onto the board so it could be soldered into place as RP3.
Completed PLL upgrade board
Once the PLL upgrade board was assembled, it was soldered into position at RP3.
PLL upgrade board soldered into position
PLL Upgrade board soldered into position
One of the many transistors soldered onto the RF board
View of the RF board
Varactor diodes added to RF board
Today I finished up on the second to the last step on page 51 of the manual. Next time I start working on the project, I will be installing capacitors on the RF board.
Hours 2:43:00 Total Build Time: 28:37:00 Nov 12, 2011
Work continued on the RF board. All of the time was spent stuffing and soldering 1/4 watt resistors.
Soldering 1/4 watt resistors on the RF board
The lighted magnifying glass really helps when soldering the components onto the board.
Checking off components as they are installed on the RF board
I found the 'Annotate' mode in "Preview" when viewing a .pdf file. I downloaded the K2 manual and errata sheet, made notes in the manual where there were changes from the errata sheet. I check off each step in the manual after installing the part. I like having the ability to also highlight, and add book marks.
Installing resistors on the RF board
Dang those parts are small. The resistors in this case are not to hard to see. There are some capacitors where the writing is so small that I even have a hard time identifying the part using the magnifying glass.
Hours 3:15:00 Total Build Time: 25:54:00 Nov 11, 2011
Its been over 24 hours now on the build time and I have finally reached the step to turn on the K2 transceiver for the first initial power up test. This test will check the front panel, Control board, and the control chip and relays on the RF board.
Well I was glad that the radio powered up with no problems the first time. As I thought about it for a while, all it would take is one component in the wrong place or with the wrong polarity, or a cold solder joint or bridge somewhere.... Well, I just have to pay attention to each step and hope that the components are ok.
Its working!
After the initial power up, there where several other checks that needed to be completed. First was the optical encoder test. This test checked to see if the display was working correctly. By pushing the rate button, I could verify that the display frequency changed correctly depending on the rate setting.
Next I tested to see if the 'band +' and 'band -' switches would cycle through all of the amateur radio bands. As the band switches were pushed, the frequency display would change to the correct band and you could hear the relays clicking to accommodate the frequency.
I skipped over the section of the manual to construct an RF probe. I decided that I would build that later when I needed it.
The next step was the construction of the 'Frequency Counter Probe'. I found the parts and began construction.
Frequency Counter Probe
To test the probe, I had to enter the 'calibration' menu. One of the menu items under the calibration section is the frequency counter. With the Frequency counter activated, I tested the trimmer capacitor C22 which is just below U1. It read 3999.98 hz which was within specs.
Next was the test of the CW keyed. I connected my keyer to the radio and it worked correctly. After that test the next test was setting the AGC threshold followed by the S-Meter alignment and 'Bargraph Current Test'. No problems at all. Each step was completed with no problems. I ended the evening by dis-assembling the chassis back down to the bare RF board. At that point, I started installing more resistors.
Adding more components to the RF board
Currently I am on page 49 of the manual. The next time that power is applied to the radio is on page 63 for the "Alignment and Test, Part II". That will be at least another week worth of work.
