[Elecraft] K1 *and* K2 Builder Alert: Front Panel Right-Angle Connector

[Wayne Burdick]

If you purchased a K1 kit that was shipped between about 12/20/02 and 3/21/03,
or a K2 kit that was shipped between about 1/14/03 and 3/21/03, you may have
received a 20-pin, right-angle connector whose pins are slightly too long. All
later K1s (S/N 1553+) and later K2s (S/N 3385+) have the correct connector pin length.

If the connector does have pins which are too long, you'll need to shorten the
pins slightly as described below. This can be done either before or after the
transceiver is assembled. You DO NOT need a new connector. Trimming the pins is
entirely satisfactory and will take only a few minutes.

The connector is designated P1 on both the K1 and K2 RF boards. To determine if
your P1 has pins which are too long and take corrective action, follow the steps below.

1. If your kit is unbuilt, locate P1, which can be found in one of the RF board
component bags. Use the photo of P1 in the RF Board parts list in Appendix A to
identify the P1. Then skip to step 5.

2. If your kit has already been assembled, remove the bottom cover (six screws).
Look closely at the point where P1 on the bottom of the RF board mates with J1
on the Front Panel board. If there appears to be a large gap between the two
connectors (about 1/16" or 1.5 mm), proceed with step 3. If there's only a small
gap--about 1/32" or less (0.8 mm or less)--then no action is required, because
the pins must be of the correct length.

3. K2 only: Remove the top cover (six screws), then remove the two screws
holding the Control board to the Front Panel board. Also remove the KAF2 module
if installed.

4. K1 or K2: Remove the four screws holding the Front Panel assembly to the
chassis. Unplug the module. (There's no need to remove the knobs or other front
panel hardware.) You should now be able to see the pins of connector P1, near
the front-center of the RF board.

5. The normal length of the straight part of the pins of P1 is 2/10", measured
from the ends of the pins to where the black plastic body begins. (2/10" is
about 13/64" or 5 mm.) The incorrect-length connectors have a straight portion
which is 3/10" (about 19/64", or 7.5 mm). If your connector has the wrong pin
length, continue with step 6. Otherwise no action is required.

6. If you're certain that you have a connector with the wrong pin length, you'll
need to trim the pins as follows. This can be done with the connector either
loose or installed.

  A. Using a fine-tip marker, make a mark about 1/16" (1.5 mm) back from the tip
of one of P1's outermost pins. (It is not necessary to trim off the entire 1/10"
(2.5 mm) excess length because the female connector on the Front Panel board can
accommodate some of the excess.)
  B. Make a similar mark on the tip of a pin at the other end of P1.
  C. Using a straight-edge aligned with both marks, draw a thin line across all
20 pins.
  D. Clip off the indicated amount of each of the 20 pins. Use diagonal or flush-cutters.

NOTE: Small variations in clipped length are OK; this will have NO effect on
performance or physical stability of the mated connection.

7. Assembled transceiver only: Reinstall the Front Panel module. Be sure to
press the Front Panel board firmly against the RF board along the bottom edge so
that the connectors become fully mated.

This builder alert will be posted on our K1 and K2 pages shortly.

Wayne,
N6KR


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