Zeppelin THE PERCOLATOR, Assembly Instructions Manual

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i. #1 Phillips
ii. #2 Phillips
iii. Small Straight
3. 12” Ruler
4. A small awl, or metal poking probe
5. Small hammer
6. Soldering Iron (not a soldering gun, or a “cold heat” iron), good quality, 15-50 watt, with a good medium or
small sized tip, conical or “screwdriver” shape. One with a temperature control and a stand is best.
7. Wet sponge or dry solder-cleaning pad
8. Wire stripper, to strip 16-, 18- and 20-gauge wire
9. Flush cutters or small diagonal cutters
10. Needle-nose pliers
11. X-Acto knife, razor blade, or scissors
12. Some sort of clamp or fixture to hold the printed circuit board and other parts while soldering (optional, but
it’s nice to work with).
13. Solder sucker or solder braid – optional, but very handy if you have to remove / repair any components!
14. Drill: cordless, corded, or drill press
15. Drill bits: 5/64, 9/64, 3/16, 7/32
16. Orbital Sander (optional) or sanding block
17. Small router and 3/16” radius roundover bit, or other small detail bit (optional)
18. Countersink (see also text below)
19. Staple gun. We prefer electric or pneumatic, but manual will work fine.
20. Sharp pencil
21. Bar clamps, minimum 12” opening, two of them
22. Speed square
23. Heat gun, or very hot hair dryer
SUPPLIES
1. Solder, 60/40 rosin core, the smaller diameter the better (we prefer .032” diameter). Make sure it’s good
quality; we prefer Kester brand, but the Radio Shack brand will work fine.
2. Isopropyl alcohol, denatured alcohol, or rubbing alcohol
3. Mineral spirits, for cleanup
4. Good quality wood glue such as TiteBond II or III
5. Good quality wood filler such as DAP Plastic Wood (optional)
6. Masking tape
7. Sandpaper, either discs for your orbital, or sheets for your block: 60, 120, 220, 320
8. Very small can of MinWax Dark Walnut Wood Finish #2716 (oil-based stain) or equal
9. Small can of MinWax Wipe-On Poly clear satin
10. A small amount of flat black paint, spray or can.
11. Clean rags