I've traced outlines for cutting the circuit board and plexiglas. I traced an extra cover so if one breaks, I've got a spare.
Oh, good. They're both the same size! I still have to cut out the hole for the bridge and pickup on the circuit board.
I've laid out the circuit on the computer. I just have to print out a mirror image on special paper, then iron it into the copper coated board.
Before I iron on the decal to affix the toner, I have to make sure the copper is clean by lightly scrubbing it with steel wool.
OK, I've ironed on the decal, peeled off the backing, then added a plastic coating to the toner on the board (another iron-on product). Before I etch the board, I have to check the integrity of the lines under my magnifying glass and remove any extra bits with my exacto knife.
Here, I've protected the rest of the board with scotch tape. I'm applying ferric chloride with a sponge (the plastic container is my reservoir - nasty stuff that stains your skin, hence the nitrile gloves). Everywhere there is green plastic or tape on the board, it won't remove the copper, but I want to completely remove it everywhere else.
The board is etched. I still have to drill holes for some of the components (some are surface-mounted). The light greenish stuff is the nonconductive epoxy circuit board under the copper conductors. It looks bigger in this photo, but this board is less than two inches long.
I've soldered on the voltage regulators, ribbon cable socket, and capacitors. I need to add the transistors (on the plate with the little vise holding the soldering iron and wiping pad), power connections, and the wire that connect to the LED board (the one that you saw me cutting out at the top of the page), then cut off the excess board (below the black ribbon cable connector) and drill mounting holes.
I still have to lay out the LED board (the one that is shaped like the front of the guitar) and the logic board (the board with the microprocessor that will control the lighting effects). Since the battery hasn't arrived yet, I'm not in a tremendous hurry but I'd like to get it finished as soon as possible so I can see it run (maybe even post a video), then ship it off, and get paid.
Making a custom circuit board isn't any harder than any other fine craft project; it merely requires a degree of care bordering on anal retentiveness. The fourteen little voltage regulators each have five legs/feet that are one millimeter apart; I had to create pads on my board for when I solder the legs/feet to the board that accommodate them but not touch the adjacent pads and cause a short circuit. This is why I make the layout on the computer, where I can magnify to my heart's content. But, I still have to print it out life-sized (that is, really tiny) and transfer the toner on the special paper to the copper, then coat it with the special plastic for etching. This requires a gentle touch to not smear the pads or otherwise goof up the transfer process. I've discovered that a black sharpie pen can touch up any breaks in the traces after I've attached the green plastic (but a blue one doesn't work). And practice, of course, makes it more likely that I'll get the outcome that I want.
I'm pretty good at soldering these finicky little bits onto the board and I've stopped losing the parts as soon as I remove them from the plastic tape/machine feed device. If you hold the soldering iron to a small pad for more than a second, the pad pulls off of the circuit board. And these are very small pads. But, if you don't heat up the pad enough, the solder won't stick. I pre-solder the pads, then attach the tiny surface-mounted devices (like the voltage regulators). I've squished ants that are bigger than these things! There is a paste solder that you can apply, then carefully place all of the devices and heat it all up in a toaster oven to melt the solder to stick down the parts, but I've never tried this method. Maybe next time. In any case, practice is the key. I'm not boasting; I AM good at soldering but this is very difficult work. But, it is very time consuming and it feels like you aren't getting anything done.But I just love creating intricate little things; if I could afford the raw materials, I probably be a jeweler.
Well, I'm tired and I'm going to bed, now. I may not get back to the board until I've done my taxes. The horror of it all!