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Posted on Monday, November 12, 2001 - 9:38 pm:   Edit Post Delete Post    Move Post (Moderator/Admin Only)

Step 1

Voyage 9000 Modification

Basic Tools Needed:

This is a listing of the basic tools needed to perform the modifications , but is by no means limited.

25 or 40 Watt Grounded Soldering Iron
60/40 Rosin Core Solder
Small Pair of Needle Nose Pliers
Small Pair of Diagonal Side Cutters or Component Shears
Desoldering Iron, Vacuum Bulb or Vacuum Powered or Desoldering Braid
Clean Work Area
Good Work Light
Phillips Screwdrivers #1 and #2
SWR-RF-Modulation Meter
Bench Type 13.8VDC Filtered Power Supply
Digital Volt Meter or Analog Meter with amperage reading capabilities
Plastic Tuning Tool to adjust trimpots *** DO NOT use a metel Jewelers will thank me later
Felt Tip or Ball Point Pen

Additional Needed Parts:

1 1N4001- Silicon Diode
1 100-Ohm 1/8 or 1/4 Watt Carbon Resistor
1 Small Piece of Heat Shrink Tubing
1 Foot of Stranded 18ga. Hookup Wire

I will use these naming conventions throughout these pages:

Front ........................... The end of the radio with the control knobs
Rear.............................. The end of the radio with the black heatsink and antenna connector
PCB ............................. Printed Circuit Board
Component Side ...... The side of the PCB that has the various electronic parts installed and their component numbers
Solder Side................. The side with the 'silver dots' (circuit pads) and circuit traces

A brief word about soldering:

Good soldering skills are essential for the successful completion of this project . Use only clean soldering tips and keep the tip well tinned (apply a small amount of solder to the tip) during the procedures. A dirty soldering tip is one main reason for poor solder connections. Applying too much heat to a component is not good either. Use only enough heat to fully melt -flow the solder when making connections. Place the tip against the part first , then add the solder, not the other way around. The solder should flow evenly, then remove the tip. If the completed joint appears dull or the solder forms a ball, either the soldering iron tip is dirty or not enough heat was applied. A good solder joint will appear shiny and be smooth in appearence. Solder, when applied to properly heated connection, will easily flow to complete the connection. Clean the tip often with a damp sponge and re-tin immediately. If you are new to soldering, find an old junk radio, and practice your soldering techinques until you feel confident. Practice removing parts from the junk PCB as well. NEVER use acid core solder. The acid flux will corrode the connection over time. Do not attemp to do this circuit board work with a 250-Watt Weller soldering gun. That's way too much heat and the tips are far too large. Too much heat can lift the circuit pads and circuit traces off of the PCB.

We will begin by removing both the top and bottom radio covers. Remove 4 screws from each side of the radio and 2 screws from the rear. Take care when removing the bottom cover, be sure to carefully unplug the speaker wire connector from the right rear PCB .

After you have removed both radio covers , place the radio in front of you, front panel knobs facing you , with the component side facing up. Now is the time to OBSERVE.....that's right....just look at the parts layout. Read this entire document and find the parts described. This is just a dry run, so that you will be familiar with the part locations when you reach that step in the modifications. Look at the pictures, turn the radio over to the solder side and find those places mentioned in the text too. When you are satisfied that you know where you will be making the changes, then proceed.

You are now ready to begin the modifications.