Full developement credit/creators(C.P.U.(2008) , Robert Petružela (Bob!k) & Radek Šterba (Raster)) is at:SDRIVE. Please refer there for their updates.
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First, you need a circuit board. I made a pcb. Do a continuity check of all traces before soldering anything. My pics are HERE. You can also hand wire. Read through these instructions several times. If you don't understand something, ask questions(chat). I ultimately ended up using the same case as I do for my Spider. It has plenty of room for parts to spread making soldering easier with a handmade board. Space board from bottom of case. I use 1/4" rubber feet. Do not put on to close to board edges....  The case this is fitted for is a Pactec #HP. Mouser#616-60616-510-000(black) #616-61989-510-039(beige) |
Flip, insert into bottom, mark locations for holes. If you are hand wiring, you can use any setup you like. See my pcb layout if you want to as an easy reference. Casepics: Sd notch-Daughterboard Mount!, Dip notch, SIO notch  If mounting the SDsocket to the foil side of the main pcb, mark the pcb level on the case, then scribe a hole about 1/16" below this, about 1/8" high(away from pcb). NOT SUGGESTED FOR THIS CASE. The daughter board can be used to remotely mount the SDsocket elsewhere with in a few inches. Fine saw the sides of all three slots. Score carefully with a razor blade across the bottom. Slowly snap out with pliers. Clean with file. The top may need the flange cut for sdcard and dip switch. The SIO jack will need about 1/4 inch more cut out of the top. With case halves together, use jack to mark height, cut out same as before. |
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At this point, you are ready to assemble the board. If you haven't done it already, use meter or battery/led/wires to check the continuity of all traces. Solder repair any that fail. Switch Prep:What you do depends on where you plan to mount the buttons and the type you choose. The large buttons need extensions to make them long enough to stick thru the case top. Prop up the pcb to get clearance. Place pins in holes lining them up. Flat side of button to left or right. Solder button pins to ext pins. Check. Re do until straight and parallel.  Soldered.  For Show ONLY at this point!The small buttons get stiff wire along their length plus about 1/2" to stiffen their leads if mounted to component side. |
Install Jumpers: You put in the five that are blue in the parts placement diagram. I have already put in one in yellow, for a connection I left off the (first) batch. I used 24ga solid wire. The two green ones are optional. The short one(tying right of R7 to top of C5) is to help with ground that can be a problem at the SDsocket. The long one also helps with ground, but secures the sd daughter board too. See SDsocket below. |
Install Resistors, capacitors(one is polarized), Diode(note dir of band, square pad gets bar end).  |
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Install IC socket(note pin 1/notch dir), voltage regulator(note dir of flat), Xtal, dip switch, SDsocket. Buttons, LEDS, SIO jack are next. |
Install SIO jack. Don't forget the screws, nuts on top.  If using the SDsocket daughter board, mount the SDsocket board upside down as shown, solder pins to foil of main pcb. If not, mount the SDsocket to the underside of the pcb. (17mar09)Here is a picture showing where to solder the SDsocket on either the main boared or the daughter board. Do not skip the stray pin on the side, else it won't know a card is inserted.(Thx Steve).  Also NOTE X:Once I drilled out the sd connector, I found a weak ground connection on the foil side. This can be fixed by placing a small solder blob at that hole.  . If you are going to mount the SDsocket on the main board foil side or you just want to reinforce the connector, two small holes can be drilled and a jumper placed on top here.  .
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Do final filing of case holes as needed. No Binding. Clean up edges. Install Switches.  Height of switch above pcb is 1 cm. Solder a couple of pins, adjust till straight, then solder other 2. Since the Red RESET button wipes settings from sdrive, you may want to mount that only 6mm high to recess it a bit. Install LEDs.  Flat goes inwards.A couple of pieces of 2.5cm long straw(slit lengthwise) makes great spacers. Do outside 2 leds, then move inwards. This shows possible way to install LEDs. Straight up in my project, out out to side, flat, or twisted.  Once all of the parts are in, trim any excess lead length from the foil side of the board. An alternate foil side parts placement is here. Use a spacer to make room to solder.  . An alternate parts placement is to use my new LED/Switch board I ake for use with the SDrive Bay Mount version. NOW is the time to check for solder bridges and cold joints on the foil side. |
Use the template or the label to locate the holes in the top for the buttons and LEDs. Start with smaller holes, file larger in the direction needed to let the components slide through easily. Should match the label if everything installed straight. Make adjustments to the case or the component as needed.  Once done, use static precautions to insert atmega chip into socket, notch towards LEDs. Make sure all of the pins are in the socket contact. Cut out top label as needed(at least 6 LED holes and 4 button holes). Test to fit, trim outside and holes as needed first(I used a 1/4" hole punch and cuticle scissors). Then peel backing and apply to clean top recess.  Card inserted, system drive(sdrive.atr) found.DONE! Another section describes my experiences in programming the atmega chip, and in actually using the sdrive. Once everything works, screw case together. P.S. What are the black rubber feet really for? Besides helping to center the SIO jack in the case, they raise the pcb up enough for the SIO jack mounting screw heads. Required to keep the jack from coming loose. |
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