though all kinds of weather. If it can stand up to this kind of abuse, it will defiantly stand up to typical daily use.
A drill template as shown below is included on the CD located in the “front panel templates” file folder so that the various
holes can be marked on the tin for drilling. Both a bit mapped (.bmp) and .pdf version is included. The bit mapped file can be
printed to scale using the “Paint” utility in Windows. [ Start > all programs > Accessories > Paint] Before you print, check the
Print Setup menu and make sure it is set to print 100% scale, not fit to page. You can also add color for making a front panel
sticker. The .pdf version will also print to scale if the proper settings are used (print 100%).
4 corner mounting holes, 7/16”
Switch and jack holes 1/4”
Fold over the edge of the template at the line to the right of the “Phones, DC IN, Paddle” labels, then place the drill template
on the outside, bottom of the tin. The hinge of the tin should be to the top. Carefully line up the template so that it is evenly
spaced between the top and bottom edges of the tin and the folded in the template is directly over the right side edge of the
tin, then tape it down. Use a sharp, pointed tool to mark the center of the holes on the tin and the center of the display
window. Then use a sharp utility knife to cut out the display window to mark the edges of the window. Before drilling the
switch and jack holes full size, drill 1/16” pilot holes first. Otherwise, the larger drill will “walk” when you drill and the holes will
not be centered properly. Drilling a clean hole in the tin isn't easy. It helps to use a reasonably new and sharp bit. Clean up
the edges with a small round file and square up the display window with a small flat file. The tin will likely deform some
around the holes. I use the end of my Xacto knife to flatten it back out.
The .bmp drill template can also be used as front panel label. Background color can be added while in the Paint program,
along with additional text or graphics if you desire. Printing on glossy photo paper with best quality print setting, then spraying
a layer of clear Krylon makes a reasonably good looking and durable label.
A piece of red film is supplied to place over the display window. I tape it in place on the outside of the tin and then cover with
the label. Double sided tape can be used to keep the edges of the label from curling up. A strip of felt can be placed over the
switches before the board is mounted into the tin to help keep dirt out of them. Cut a small slit in the felt for the switch buttons
to poke through.
Before the board will sit properly in the tin, the edges of the board on the side with the jacks will have to be rounded. Snip the
corner off the board with your cutters and then round the edges with a file, back to nearly the edge of the mounting stand off.
When putting the board into the tin, you will have to press slightly to make it snap past the rolled edges of tin. Secure the
board to the tin with the four #2 screws. Install the RCA antenna jack and jumper the center pin to the “ANT” pad on the
board and the ground lug to the near-by ground plane pad on the board.
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