Electronic & Electronic & Mechanical assemblyMechanical assembly

Jerry Ernst / JerroStomp

Kit Assembly

• Some assemblies are “simply” kit builds

Some are not so simpleEvery component has to be exactly in the right place, many in the correct orientation.

Some builds are modified kits• Three capacitor values were increased to pass

more low frequencies• Two resistors were reduced in order to increase

the maximum gain• Note, all exteriors are my own design

The next step:

• Bread boarding old schematics and enhancing them with new components and circuit changes

Enclosure design• Lay out jacks and switches to avoid electrical

problems, drill enclosures to final design locations with drill press

• Design catchy graphics• In home-built ‘clean’ enclosure apply primer, 2

base coats, bake, add decals, and 3 clear coats, heat treat w/ hot air

Transfer optimized circuit from B-Board to perf board

• Draw schematic & BOM, build, test, then document the build process for repeatability

Next Step (underway)

• Study basic DC electronics, learn the math behind circuit building, and develop new circuit concepts from the ground up, including etching of circuit boards

Quality Systems• Follow every process step as a checklist• For new circuits, document process, then follow it per 1st

step• Inspect EVERY solder joint under magnification, both

sides of the board• Measure EVERY resistor before installing• Check all joints to ground• Measure and record key voltages• Maintain build notebook and photograph every circuit

board, both sides, before assembly• Run each completed build through all settings and assure

proper functionality, exceptional tonal quality, and low noise operation both for battery and adapter operation.

Cable Building• Use the finest components• Pre-tin all wires and the ground boat• Use hemostat heat sinks to protect cable while making solid solder

connections• Hook and crimp the hot wire for full mechanical connection before

soldering• Use heat shrink to support clamping connection and provide strain

relief where applicable• Test 100% for tonal range