After winning an online auction for an 1980s vintage Compaq Portable PC, [leadacid44] discovered why it only cost him $5USD – the keyboard was shot. Not willing to accept having forked out $45USD to ship a brick, he tore into the ancient machine and came up with a found-material solution to the wonky keyboard.
[leadacid44]’s very detailed writeup of the fix for his Compaq includes a thorough examination of the guts of the machine. He got it to boot to MS-DOS 5.0 off of a 20MB ISA hard drive card and began probing the keyboard problem. It turns out the Compaq keyboard has much in common with a modern touchscreen, in that it’s a capacitive keyboard. Unfortunately the foam disks used as springs under each key cap had degraded over the last 30 years, so [leadacid44] began a quest to replace them. After much experimentation and a few false starts, he created a sandwich of transparency film, closed-cell polyethylene foam, and a Mylar antistatic bag. Many discs were punched out with a leather punch and tediously placed in the body of each key switch, and the quick brown fox was soon jumping flawlessly over the lazy dog.
We’ve seen some fixes to these lovable luggables before, like this dumpster queen that became a Hackaday Retro submission. At least [leadacid44]s machine didn’t release the Magic Blue Smoke like that one did.
When you think about the difficulties of working with surface mount components, the first thing that often comes to mind is trying to solder those tiny little parts. Instead of soldering those parts by hand, you can actually apply solder paste to the pads and place all of the components on at once. You can then heat up the entire board so all of the parts are soldered simultaneously. It sounds so much easier! The only problem is you then need a solder stencil. You somehow have to get a thin sheet of material that has a perfectly sized hole where all of your solder pads are. It’s not exactly trivial to cut them out by hand.
[Juan] recently learned a new trick to make cutting solder stencils a less painful process. He uses a laser cutter to cut Mylar sheets into stencils. [Juan] appears to be using EagleCAD and Express PCB. Both tools are available for free to hobbyists. The first step in the process is to export the top and bottom cream layers from your CAD software.
The next step is to shrink the size of the solder pads just a little bit. This is to compensate for the inevitable melting that will be caused by the heat from the laser. Without this step, the pads will likely end up a little bit too big. If your CAD software exports the files as gerbers, [Juan] explains how to re-size the pads using ViewMate. If they are exported as DXF files, he explains how to scale them using AutoCAD. The re-sized file is then exported as a PDF.
[Juan’s] trick is to actually cut two pieces of 7mil Mylar at the same time. The laser must be calibrated to cut all the way through the top sheet, but only part way into the bottom piece. The laser ends up slightly melting the edges of the little cut out squares. These then get stuck to the bottom Mylar sheet. When you are all done cutting, you can simply pull the sheets apart and end up with one perfect solder stencil and one scrap piece. [Juan] used a Full Spectrum 120W laser cutter at Dallas Makerspace. If you happen to have this same machine, he actually included all of the laser settings on his site.