Ron,
Thank you for the detailed reply. I have shortened your response
below, and inserted my comments.
Ron D'Eau Claire wrote:
Tue, 29 Apr 2008 13:28:14 -0700
I've only received sporadic reports of this happening, and *nothing*
after
suggesting checking the fit of the mic connector, which led me to
believe
the problem was fixed as suggested....
My mic connector does clear the hole, as in Fig. 37.
... Among the returns they have noticed several that did not have
the split ring
lock washer between the standoff and the pc board as shown in Figure
34 of
the assembly manual. Instead the builder put the washer under the
head of
the screw because that’s where one might expect to put a lock
washer, but
that is *not* where it goes. ...
I'm certain I did it as described.
In this case it is part of the total spacer
provided by the standoff and must go between the standoff and the pc
board.
That mistake actually helps the PHONES washer fit more tightly by
moving
everything forward toward the sheet metal, but can result in a
skewed VFO A
shaft since the connector 'bottoms out' in the jack on the front
panel PC
board before it sits squarely behind the front panel.
In that case, I suppose I would have seen the threaded shaft draw
outward as I snugged the nut. I used a box-end wrench and watched, and
didn't see that happening. I think the toothed lockwasher on the
inside crushed more on one side. Since I had 6" wrench leverage, I
followed temptation and made it pretty tight, maybe more than
intended? - but not extreme. I do have some finesse. I suppose I could
try tightening it more, to see if it straightens out.
Adding the nut inside
the front panel will move the VFO A encoder back and solve that
problem, but
it can cause fit issues in the future as you add options.
Another problem that mistake causes are occasional broken LCD glass
because
the display is moved forward with the front panel board where the
screws
holding the LCD cover can strike it.
So far, they have found they can fix loose PHONES jack washers and
crooked
VFO A encoders by tightening the nuts sufficiently. As one builder
mentioned, the knurled nut defies too much tightening with a tool
unless one
risks scratching the front panel. What the folks in Aptos have done
is to
squeeze the front panel sheet metal back against the PC boards in
one hand,
pressing *between* the jack and the red and yellow LEDs just above
it (but
not ON the LEDs) with a thumb while supporting the PC boards with
their
fingers from behind. That flexes the sheet metal just slightly but
enough to
allow them to tighten the PHONES knurled nut with the fingers of the
other
hand to trap the washer securely. So far, that has cured all the loose
washers they have encountered assembling rigs.
That's what I did when I assembled it, since I didn't think just
finger-tight would do. I got it tighter that way, but still, it
loosened as soon as I plugged headphones in a couple times.
They also reported getting a few K3s back with complaints about a
crooked
VFO A encoder that was fixed simply by tightening the nut against
the front
panel. It was finger tight, but not tight enough. A little extra
leverage on
the nut straightened up the shaft.
See above. Mine IS pretty tight.
Of course, both of those "fixes" can cause serious damage if the
front panel
is not properly spaced from the front panel board using the 5/16"
standoffs
and split lock washers as shown in the manual.
I guess I'm safe there.
An obvious question is "how tight is too tight" so that it might break
something. I have assembled two front panels, and both times nominal
pressure with pliers (or a socket wrench held in my hand - no handle
attached) was plenty. But two is a tiny sample. It would be good to
hear
from those who have the "loose Phones washer" and "crooked VFO A
encoder"
problems and whether any of the above helped, should you be inclined
to take
another look.
Feel free to drop me a note if you're experiencing these problems
and let me
know if the above help.
Ron
If I can find some fix for the loose PHONES jack, I'll be happy to
leave the encoder shaft as it is, unless you suggest I tighten it a
bit more (trusting my good judgement) but now that I recall from the
photo how slim the lock washers are, I'm more inclined to leave well
enough alone.
Thanks!
Windy_______________________________________________
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