Nearly-Destroyed Commodore Gets New Life

April 26, 2024 by Bryan Cockfield 5 Comments

We all have our shiny, modern computers for interacting with the modern world, but at times they can seem a little monochromatic. Even the differences between something like macOS and Windows for the average user often boil down to which operating system loads an Internet browser. There are obviously more differences than that, but back in the 80s it was much more extreme with interoperability a pipe dream in most cases. What keeps drawing people to maintaining and using computers from that chaotic era is more tangible compared to modern machines, and that is meant quite literally; computers from this era can be saved from an extreme amount of degradation like this Commodore that was nearly completely destroyed before it was re-discovered.

The first step was to restore the case of this Commodore PC20-III, but the restoration of the computer’s internals took a bit more time. First, the entire board was de-soldered, with any rare chips being set aside for future use. Unfortunately the board itself was too corroded and otherwise damaged to be used, but since these were just two-layer boards it could be photographed and then re-created in CAD software to make a near-perfect duplicate of the original. The team at [The Cave] took the opportunity to add patch wires which would have been present in the original machine into the PCB, and made some other upgrades as well like adding sockets to various chips that would have been originally soldered to the board.

The passive components, especially capacitors, were brand new as well and some period-correct components such as a monitor and keyboard finish out the build. The computer boots on the first try, and is quickly put through its paces testing the hard disk drive, using the old floppy drive, and even playing a few video games from the era. The fact that retrocomputers like these are easy (by modern standards) to reverse engineer and restore surely leads to their continued popularity, and we’ve seen everything from C64s to this 128DCR get a similar full restoration.

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Reverse Engineering The Quansheng Hardware

April 23, 2024 by Dan Maloney 11 Comments

In the world of cheap amateur radio transceivers, the Quansheng UV-K5 can’t be beaten for hackability. But pretty much every hack we’ve seen so far focuses on the firmware. What about the hardware?

To answer that question, [mentalDetector] enlisted the help of a few compatriots and vivisected a UV-K5 to find out what makes it tick. The result is a complete hardware description of the radio, including schematics, PCB design files, and 3D renders. The radio was a malfunctioning unit that was donated by collaborator [Manuel], who desoldered all the components and measured which ones he could to determine specific values. The parts that resisted his investigations got bundled up along with the stripped PCB to [mentalDetector], who used a NanoVNA to characterize them as well as possible. Documentation was up to collaborator [Ludwich], who also made tweaks to the schematic as it developed.

PCB reverse engineering was pretty intense. The front and back of the PCB — rev 1.4, for those playing along at home — were carefully photographed before getting the sandpaper treatment to reveal the inner two layers. The result was a series of high-resolution photos that were aligned to show which traces connected to which components or vias, which led to the finished schematics. ~~There are still a few unknown components~~, The schematic has a few components crossed out, mostly capacitors by the look of it, representing unpopulated pads on the PCB.

Hats off to the team for the work here, which should make hardware hacks on the radio much easier. We’re looking forward to what’ll come from this effort. If you want to check out some of the firmware exploits that have already been accomplished on this radio, check out the Trojan Pong upgrade, or the possibilities of band expansion. We’ve also seen a mixed hardware-firmware upgrade that really shines.

PCB Design Review: Tinysparrow, A Module For CAN Hacking Needs

April 3, 2024 by Arya Voronova 21 Comments

I enjoy seeing modules that can make designing other devices easier, and when I did a call for design reviews, [enp6s0] has submitted one such board to us. It’s a module called TinySparrow (GitHub), that helps you build your own vehicle ECUs and any other CAN-enabled things. With a microcontroller, plenty of GPIOs, a linear regulator and a CAN transceiver already onboard, this board has more than enough kick for anyone in hobbyist-range automotive space – and it’s surprisingly tiny!

You could build a lot of things around this module – a CAN bus analyzer or sniffer, a custom peripheral for car dashes, or even a full-blown ECU. You can even design any hardware for a robot or a piece of industrial technology that uses CAN for its backbone – we’ve all seen a few of those! It’s a great board, but it uses six layers. We’ll see if we can do something about that here.

Modules like TinySparrow will make your PCBs cheaper while ordering, too! Thanks to the carefully routed microcontroller and the CAN transmitter, whatever board you design around this chip definitely wouldn’t need six layers like this one does – and, unlike designing your own board, you can use someone’s well-tested and tailored libraries and reference circuits!

With TinySparrow, you save a lot of time, effort and money whenever you want to design a car or industrial accessory. After looking at the board files, my proposal for helping today’s board is – like last time – to make its production cheaper, so that more people can get this board into their hands if the creator ever does try and manufacture it. I also have some tips to make future improvements on this design easier, and make it more friendly for its userbase.

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Faux Silkscreen On A PCB Made With A Laser Cutter

March 18, 2024 by Lewin Day 11 Comments

If you’re getting PCBs professionally made, silkscreen usually comes free as part of the package. However, if you’re making your own, the job is on you. [Tony Goacher] makes his own PCBs on a CNC router, so he’s not getting any silkscreening as part of that bargain. But he wondered—could he do something analogous with a laser cutter?

The answer is yes. The silkscreen layer was first exported from DesignSpark, with the file then sent to LightBurn to prep it for laser cutting. The board outline layer was first engraved on to a piece of scrap as an alignment aid. Then, the board was placed in the laser cutter, with the silkscreen scorched directly on to the fiberglass.

The results are encouraging, if imperfect. [Tony] says he ran at “quite fast speed at quite high power.” The markings are all there, but they’re a little melty and difficult to read. He noted at lower speeds and lower power, the results were a bit more readable.

PCBs aren’t really an ideal engraving or laser marking material, but this technique could be servicable for some basic markings on DIY PCBs. We look forward to seeing how [Tony] improves the process in future. Video after the break.
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Proper Routing Makes For Many Happy Return Paths

March 18, 2024 by Dan Maloney 18 Comments

Here’s a question for you: when your PCB has a ground plane layer, where do return signals flow? It seems like a trick question, but as [Kristof Mulier] explains, there’s more to return path routing (alternate link in case you run into a paywall) than just doing a copper pour and calling it a day.

Like so many other things in life, the answer to the above question is “it depends,” and as [Kristof] ably demonstrates in this concise article, the return path for a signal largely depends on its frequency. He begins by explaining current loop areas and how they factor into the tendency for a circuit to both emit and be susceptible to electromagnetic noise. The bigger the loop area, the worse things can get from a noise perspective. At low frequencies, return signals will tend to take the shortest possible path, which can result in large current loop areas if you’re not careful. At higher frequencies, though, signals will tend to follow the path of minimal energy instead, which generally ends up being similar to the signal trace, even if it has a huge ground plane to flow through.

Since high-frequency signals naturally follow a path through the ground plane that minimizes the current loop, that means the problem takes care of itself, right? It would, except that we have a habit of putting all kinds of gaps in the way, from ground plane vias to isolation slots. [Kristof] argues that this can result in return paths that wiggle around these features, increasing the current loop area to the point where problems creep in. His solution? Route all your signal return paths. Even if you know that the return traces are going to get incorporated into a pour, the act of intentionally routing them will help minimize the current loop area. It’s brilliantly counterintuitive.

This is the first time we’ve seen the topic of high-frequency return paths tackled. This succinct demonstration shows exactly how return path obstructions can cause unexpected results.

Thanks to [Marius Heier] for the tip.

Fabbing A Fab New Watch Face

March 7, 2024 by Kristina Panos 7 Comments

[STR-Alorman] is into vintage watches, particularly Omega Seamaster quartz numbers from the 1980s. Among his favorites is the Seamaster Calypso III, a precious few of which were created in a lovely and rare black-on-black colorway. [STR-Alorman] found one on online, but it had a number of problems including a scratched-up face. Having done a respectable amount of PCB design and assembly, he decided to make a new face and have it fabbed.

The one angle where you can even tell this is a PCB.

After taking scale-referenced photos with a DSLR, [STR-Alorman] created vectors in Illustrator and then ported those to KiCad. He sent two versions to the board house — one with holes at index points, and one without — because he wasn’t sure which would be better for applying the luminization compound that makes them glow. Spoiler alert: it was the one with the cutouts.

Once this was done, [STR-Alorman] reassembled the movement, which doesn’t look easy at all, and involved getting the height of a bit of CA glue just right so as not to interfere with the movement of the date wheel. He replaced the bezel insert, re-luminized the hands, and now has a beautiful timepiece.

We believe only the nerdiest of nerds could tell this is a PCB, and they would need exactly the right light to make that determination. Here’s a watch that leaves no doubt about it.

Replacement PCB Replicates Early 80s Modem

February 21, 2024 by Bryan Cockfield 27 Comments

It’s certainly been a few decades, but plenty of us remember a time before widespread access to broadband internet, when connections were generally made over phone lines using acoustic modems. In the 90s these could connect you to AOL and Napster well enough, but in the early 80s the speeds were barely enough to read text as it loaded. A company called Hayes set out to change this with some of the first useful, widely-available modems for the PCs at the time. While they couldn’t keep up with the changing times there’s still a retro community that has these antiques, and to modernize it a bit this drop-in replacement for the PCBs replicates these old modems almost exactly.

The new PCB is equipped with everything needed to get a retro computer online again, including all the ports to connect a computer without any further modifications. It houses a few modern upgrades beyond its on-board processors, though. Rather than needing an actual acoustic coupled phone, this one has an ESP32 which gives it wireless capability. But the replacement PCB maintains the look and feel of the original hardware by replicating the red status LEDs at the front, fitting into the original Hayes cases with no modifications needed at all, and even includes a small speaker through which it can replicate the various tones, handshakes, and other audio cues that those of us nostalgic for this new online era remember quite well.

For those looking for a retro feel without the hassle of getting antique networking equipment functional again, this type of upgrade that preserves the essence of the original hardware is an excellent way of keeping retro computers functional on modern networking equipment. But if you absolutely must get the networking equipment exactly right down to the last patch cable, you might end up having to build your own ISP from scratch.

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