So Saturday morning I decided to start my build around 10am. I had a cup of expresso double shot (just because we prepare in the event something bad happens doesn't mean we can't live it up now!!!) So I started to unpack everything, there were a million little packages, so i weeded through and laid them all out on my work space. I opened just the main hardware bag and sorted it out into muffin cook sheets. For future kit builders reading this, DO NOT SKIP THIS PART. There are certain screws that look to be very close in size, but are a little different in size. Go by the amounts and try to find all the matching pieces, label them out, and put in seperate containers. I ran out of space so I had to double up in some compartments, but do it smartly and put in parts that you can't confuse. IE nuts and Bolts, or front face buttons and knobs. There are a few assembly places that if you put in the wrong screws you will create a short and blow the entire thing up. Once I got the pieces sorted I went at it.
First step was to take out the main RF board:
You can see the edge of the muffin pans up top. This board came just like you see it, I just took it out of the package.
The first part was to put on a few of the standoffs and various nuts and bolts which we will be using to mount up the shell to later, Then we install the filter. I only got the stock filter, but you can see slots for filters 1-5. I might get some additional ones later, Just slide it in, line up connectors, and screw it down from under the board.
Next I slip the LPA (low power amplifier) board into the large hole in the middle. It simply slides in, once the connectors are lined up, and friction holds it in place, Easy does it here, the main board and everything else starts flexing and you don't want to break it!
Next up we mount up the bracket for the face plate. Nothing tricky here, just a couple screws.
Next in is the mixer board. The small board down near the bracket, with the screw in it.
Next assembly of the left wall side.. We attach the handle.
Bolting up the left side to the RF board, and the front face bracket.
Aerial shot of the left side after attachment:
We start working to assemble the back Plate now, and begin to put the antenna connections on it.
The back
The inside:
Mounting the second connection:
Now we slide the KAT3 the Antenna tuner into the main RF board:
side view:
Time to put the back plate on and connect it so the side and the rf board!
Aerial shot of the back:
Mount the right panel now, and it starting to take shape!
We install the kxv3 board into the back panel and connect to RF board now, this board allows up to make connection to panadapters and other devices.
Here is a view from the outside of the case, you can see the connections, the panadapter (band scope) connects into the IF out here:
We not connect in and bolt up the remaining interfaces on this back part of the board the kio3 and the audio interfaces
Put the case aside and it's time to assemble the front face of the unit.
Here is a shot of the front:
and back of the control panel:
We mount some standoffs and put the front panel on it:
On go the knobs!
Slip the DSP board on to the back of the front panel:
Now bolt the entire assembly onto the case
Time for the moment of truth!! THE SMOKE TEST!!
No smoke!! And it lights up just fine!! The Error is normal, the IF board isn't installed yet!
Here she is, plugged in.. Go ahead and take all night trying to find smoke.. There is none!!
It's time to mount the syn board, and the reference module. They both bolt to the back back of the front case bracket:
Assemble the bottom of the unit, this is the "front" piece:
We mount the RF shield now in preparation to mount the 100w amplifier, after calibration.
Mount both the bottom pieces onto the unit.. Look at the carnage in the background it's been a long day!!
Slap the top on, and we have a completed unit!! Well, minus the 100w amp, which is just a drop in, and 3 screws, Time to calibrate!
The last pic of it calibrating.
http://www.elecraft.com/K3/K3.htmOn a 1-10 scale of difficulty this was a 4 or maybe a 5. Certainly not as hard as the old kits, that require soldering.
Tools I needed and used:
Screw driver, smaller ones
I did solder the anderson power pole connectors on
signal generator
100w dummy load
multi meter, at one point you need to measure resistance across a few areas to make sure you aren't grounding out anything. Mine was fine first try.
This was a real fun project, took about 12 hours from the time I started until the time I was on the air. Had some minor calibration issues, and some other issues that I will elaborate on in a later post..
Price: 1999$ Assembled 2499$