9
the top for a few seconds to allow the adhesive to spread underneath the part. The
component will have some play in the plated through holes, allowing it to rock and back
and forth slightly; adjust it so that it’s sitting upright and not tilted to one side.
4.
Repeat steps 2 and 3 for the other five capacitor footprints (C3B, C5A, C5B, C8A, C8B).
Note that you’ll need a little more adhesive as the components get larger.
5.
Now that all six of these capacitors are placed on the board, take a break and let the
adhesive cure for a while before proceeding to solder them all in. If you are using the
E6000 adhesive we recommended earlier in this manual, the advertised cure time is 24
hours for a full cure, but depending on the temperature in your work area, one hour or
slightly more should allow for a sufficiently stable bond to start soldering.
6.
Solder the leads for the six capacitors you’ve installed so far and clean off all the flux
residue when you are done.
Phase 3: Capacitors C1A and C1B
1.
Locate the 27µF and 30µF capacitors for positions C1A and C1B.
2.
Follow the same procedure from steps 1 through 3 in Phase 2 to install these capacitors.
Phase 4: Inductor L1
1.
Locate the 1.0mH air core inductor for position L1.
2.
Start by doing a fit check
-
arrange the leads to fit through the plated through holes, while
positioning the inductor so that it sits flat on the board (see Figure 3 for reference). The
leads will be much longer than required for the given footprint, so trim off the excess
length, leaving enough to pass through the board and allow for a solder fillet on both
sides.
3.
Now that you’ve trimmed off the excess leads to the desired length, you’ll need to
remove the enamel coating at the ends of the wire and tin the wire, so that it will solder
properly to the pads. This
YouTube video
provides a great tutorial on how to do this.
4.
With the inductor removed from the board, thread a zip tie through the two holes on the
inductor footprint such that the zip tie is looped through the bottom of the board, and both
ends of the zip tie are pointing upwards. Leave the zip tie open for now.
5.
As you did with the capacitors previously, place a dab of adhesive on the inductor
footprint, big enough that it will cover the mounting surface of the inductor with the
squeeze out, but not big enough that it will make a mess.
6.
Place the inductor onto the footprint, with the leads inserted into the plated through holes,
and press down gently in the center to seat it in the adhesive. Carefully fasten the zip tie
so that it will clamp around the lower portion of the coil that is resting flush against the
board, tighten the zip tie, and snip off the excess. Allow the adhesive to cure for about
an hour before proceeding to the next step.
7.
Solder the two inductor leads to the PCB.
At this point, you should now have two fully assembled boards with all capacitors and inductors
soldered and adhered to the board. Walk away, take a well
-
earned break, have an adult beverage,
etc., and allow all of the adhesive to cure for the full recommended cure time overnight before
proceeding to install the boards into the crossover assemblies.
