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[K3] Assembly question

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Mike Reublin

[K3] Assembly question

When I built my K3, I was not able to get a tight enough fit between the
DSP board and the front panel to keep that thick washer (that goes over
the phone jack) from rattling.

I pulled the DSP board this morning to send in for the upgrade, and
would like to fix the washer when I re-install it. Any tips, or am I
making a molehill out of a flat plat?

73, Mike NF4L

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Mike Reublin

Re: [K3] Assembly question

And what's the washer's purpose?

Mike wrote:

> When I built my K3, I was not able to get a tight enough fit between the
> DSP board and the front panel to keep that thick washer (that goes over
> the phone jack) from rattling.
>
> I pulled the DSP board this morning to send in for the upgrade, and
> would like to fix the washer when I re-install it. Any tips, or am I
> making a molehill out of a flat plat?
>
> 73, Mike NF4L
>
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>

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DaveL G3TJP

Re: [K3] Assembly question

In reply to this post by Mike Reublin

It was a bit loose on my K3 #1122, but I've seen it as a close fit on other K3's and a slack fit on a couple of others.

Mine rattled when the internal speaker was used so I put a little bit of stuff called Blu-Tak on mine to stop it rattling. Subsequently, on removing the DSP from the front panel to make changes, I used a tiny dot of superglue to fix it to the front panel. After finger tightening the nut on the jack socket there's still a tiny gap but it doesn't rattle any more.

73 DaveL G3TJP
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Mike Reublin

Re: [K3] Assembly question

Thanks, David.

I'm considering just leaving it out, it seems to serve no purpose.

73, Mike NF4L

David Lankshear wrote:

> It was a bit loose on my K3 #1122, but I've seen it as a close fit on other K3's and a slack fit on a couple of others.
>
> Mine rattled when the internal speaker was used so I put a little bit of stuff called Blu-Tak on mine to stop it rattling. Subsequently, on removing the DSP from the front panel to make changes, I used a tiny dot of superglue to fix it to the front panel. After finger tightening the nut on the jack socket there's still a tiny gap but it doesn't rattle any more.
>
> 73 DaveL G3TJP
> ______________________________________________________________
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M0XDF

Re: [K3] Assembly question

I think it acts as a spacer and prevents you distorting the board by pulling it too close.
Get the nut tight enough and it doesn't rattle
73 de M0XDF, K3 #174
--
The trees that are slow to grow bear the best fruit.
-Moliere, actor and playwright (1622-1673)

On 17 Mar 2010, at 13:04, Mike wrote:

> Thanks, David.
>
> I'm considering just leaving it out, it seems to serve no purpose.
>
> 73, Mike NF4L
>
> David Lankshear wrote:
>> It was a bit loose on my K3 #1122, but I've seen it as a close fit on other K3's and a slack fit on a couple of others.
>>
>> Mine rattled when the internal speaker was used so I put a little bit of stuff called Blu-Tak on mine to stop it rattling. Subsequently, on removing the DSP from the front panel to make changes, I used a tiny dot of superglue to fix it to the front panel. After finger tightening the nut on the jack socket there's still a tiny gap but it doesn't rattle any more.

Don Wilhelm-4

Re: [K3] Assembly question

In reply to this post by Mike Reublin

Mike,

Do not leave it out. That washer is a spacer.
Apply pressure between the board and the front panel metalwork and
tighten the nut until the washer is firmly captive.

If you have the board plugged in correctly, nothing will be harmed. If
you don't have the board pluggin in correctly, it should be obvious
because you will not be able to engage the nut on the phone jack.

73,
Don W3FPR

Mike wrote:
> Thanks, David.
>
> I'm considering just leaving it out, it seems to serve no purpose.
>
> 73, Mike NF4L
>
>
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Don Wilhelm-4

Re: [K3] Assembly question

I might add that if the spacer is left off, the DSP board will flex
every time the Phone plug is removed and can lead to future failure.

73,
Don W3FPR

Don Wilhelm wrote:

> Mike,
>
> Do not leave it out. That washer is a spacer.
> Apply pressure between the board and the front panel metalwork and
> tighten the nut until the washer is firmly captive.
>
> If you have the board plugged in correctly, nothing will be harmed. If
> you don't have the board pluggin in correctly, it should be obvious
> because you will not be able to engage the nut on the phone jack.
>
> 73,
> Don W3FPR
>
> Mike wrote:
>
>> Thanks, David.
>>
>> I'm considering just leaving it out, it seems to serve no purpose.
>>
>> 73, Mike NF4L
>>
>>
>>
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>
>
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> Checked by AVG - www.avg.com
> Version: 9.0.733 / Virus Database: 271.1.1/2752 - Release Date: 03/17/10 03:33:00
>
>

Terry Schieler

Re: [K3] Assembly question

In reply to this post by DaveL G3TJP

My washer was quite loose on the build of K3 #474. The rattle bothered me
on such an otherwise fine piece of engineering. Elecraft service said they
had heard of it once before and that I probably didn't have the front panel
seated properly. Then I began to read that many others had the problem on
their K3's. So I added a dab of hot glue to the washer and it rattles no
more.

Just FYI, when I snugged the nut down enough to stop the washer from
rattling, I could see the front panel visibly bending under the force
(fingers only). So I backed the washer off to where it was just snug (and
the panel stopped bowing) and went with the hot glue fix.

Terry, W0FM

-----Original Message-----
From: David Lankshear [mailto:[hidden email]]
Sent: Wednesday, March 17, 2010 7:53 AM
To: [hidden email]
Subject: Re: [Elecraft] [K3] Assembly question

It was a bit loose on my K3 #1122, but I've seen it as a close fit on other
K3's and a slack fit on a couple of others.

Mine rattled when the internal speaker was used so I put a little bit of
stuff called Blu-Tak on mine to stop it rattling. Subsequently, on removing
the DSP from the front panel to make changes, I used a tiny dot of superglue
to fix it to the front panel. After finger tightening the nut on the jack
socket there's still a tiny gap but it doesn't rattle any more.

73 DaveL G3TJP

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Mike Reublin

Re: [K3] Assembly question

In reply to this post by M0XDF

If I get the nut that tight, for sure I'm going to distort or break
something. :-(

73, Mike NF4L

David Ferrington, M0XDF wrote:
> I think it acts as a spacer and prevents you distorting the board by pulling it too close.
> Get the nut tight enough and it doesn't rattle
> 73 de M0XDF, K3 #174
>

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Mike Reublin

Re: [K3] Assembly question

In reply to this post by Don Wilhelm-4

Thanks, Don,

If I pull the nut up that tight, I'm afraid I'll distort or break
something. I can't measure it right now, but it's a pretty big gap
(meaningless phrase, I know). I'll look closer when the DSP board gets back.
All it has to do is just touch, right?

Mike

Don Wilhelm wrote:

> I might add that if the spacer is left off, the DSP board will flex
> every time the Phone plug is removed and can lead to future failure.
>
> 73,
> Don W3FPR
>
> Don Wilhelm wrote:
>> Mike,
>>
>> Do not leave it out. That washer is a spacer.
>> Apply pressure between the board and the front panel metalwork and
>> tighten the nut until the washer is firmly captive.
>>
>> If you have the board plugged in correctly, nothing will be harmed.
>> If you don't have the board pluggin in correctly, it should be
>> obvious because you will not be able to engage the nut on the phone
>> jack.
>>
>> 73,
>> Don W3FPR
>>
>> Mike wrote:
>>
>>> Thanks, David.
>>>
>>> I'm considering just leaving it out, it seems to serve no purpose.
>>>
>>> 73, Mike NF4L
>>>
>>>
>> ______________________________________________________________
>> Elecraft mailing list
>> Home: http://mailman.qth.net/mailman/listinfo/elecraft
>> Help: http://mailman.qth.net/mmfaq.htm
>> Post: mailto:[hidden email]
>>
>> This list hosted by: http://www.qsl.net
>> Please help support this email list: http://www.qsl.net/donate.html
>> ------------------------------------------------------------------------
>>
>>
>> No virus found in this incoming message.
>> Checked by AVG - www.avg.com Version: 9.0.733 / Virus Database:
>> 271.1.1/2752 - Release Date: 03/17/10 03:33:00
>>
>>
>

Mike Reublin

Re: [K3] Assembly question

In reply to this post by Terry Schieler

Thanks, Terry,

Yeah, I don't want to bend anything. I'm pretty sure the board is seated
properly, as it is in contact with the stand-offs. Maybe the stand-offs
are a tad long.

Don's explanation that the purpose is to keep the DSP board from flexing
sounds good, so leaving it out isn't the best idea I've had. If I can't
tighten it enough, I m thinking I may stack some more washers with it,
making sure they don't contact anything they shouldn't.

If it's a problem on more than a coupe (and it seems to be), I'm really
surprised that Elecraft hasn't addressed it.

73, Mike NF4L

Terry Schieler wrote:

> My washer was quite loose on the build of K3 #474. The rattle bothered me
> on such an otherwise fine piece of engineering. Elecraft service said they
> had heard of it once before and that I probably didn't have the front panel
> seated properly. Then I began to read that many others had the problem on
> their K3's. So I added a dab of hot glue to the washer and it rattles no
> more.
>
> Just FYI, when I snugged the nut down enough to stop the washer from
> rattling, I could see the front panel visibly bending under the force
> (fingers only). So I backed the washer off to where it was just snug (and
> the panel stopped bowing) and went with the hot glue fix.
>
> Terry, W0FM
>
> -----Original Message-----
> From: David Lankshear [mailto:[hidden email]]
> Sent: Wednesday, March 17, 2010 7:53 AM
> To: [hidden email]
> Subject: Re: [Elecraft] [K3] Assembly question
>
> It was a bit loose on my K3 #1122, but I've seen it as a close fit on other
> K3's and a slack fit on a couple of others.
>
> Mine rattled when the internal speaker was used so I put a little bit of
> stuff called Blu-Tak on mine to stop it rattling. Subsequently, on removing
> the DSP from the front panel to make changes, I used a tiny dot of superglue
> to fix it to the front panel. After finger tightening the nut on the jack
> socket there's still a tiny gap but it doesn't rattle any more.
>
> 73 DaveL G3TJP
>
>
> ______________________________________________________________
> Elecraft mailing list
> Home: http://mailman.qth.net/mailman/listinfo/elecraft
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> Post: mailto:[hidden email]
>
> This list hosted by: http://www.qsl.net
> Please help support this email list: http://www.qsl.net/donate.html
>
>

N5GE

Re: [K3] Assembly question

In reply to this post by DaveL G3TJP

On Wed, 17 Mar 2010 12:53:00 -0000, "David Lankshear"
<[hidden email]> wrote:

I presume you considered that if there was ever a reason to remove the
washer in the future, you may have to damage the front panel to remove
it, and decided that was not an important issue.

>It was a bit loose on my K3 #1122, but I've seen it as a close fit on other K3's and a slack fit on a couple of others.
>
>Mine rattled when the internal speaker was used so I put a little bit of stuff called Blu-Tak on mine to stop it rattling. Subsequently, on removing the DSP from the front panel to make changes, I used a tiny dot of superglue to fix it to the front panel. After finger tightening the nut on the jack socket there's still a tiny gap but it doesn't rattle any more.
>
>73 DaveL G3TJP

Tom, N5GE

K3 #806 with SUB RX, PR6,
KRC2 and K144XV
K3 #1055 with PR6 and XV432
W1, 2 W2's and other small kits

http://www.n5ge.com
http://www.swotrc.net

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Amateur Radio Operator N5GE

DaveL G3TJP

Re: [K3] Assembly question

In reply to this post by Mike Reublin

The fitting of the washer is indeed a trivial matter, Tom. It's on the
inside of the front panel, so if it had to be chiseled off, the marks
wouldn't show and I'm sufficiently competent to use the minimum
amount of adhesive to hold it in place. I won't tighten down the nut
on the front panel beyond finger tight because it would distort the
panel and probably damage the panel coating, besides being quite
unnecessary. A gap of a few thou is irrelevant to the washer's fitting
and function, but a large gap, such as would remain if the washer was
not in place, would potentially stress the DSP board unreasonably, as
pointed out by Don. A rattling washer is a nuisance and stopping that
by whatever means - adhesive, hotmelt, Blu-tak, chewing gum etc. is
a positive contribution to the K3's usability.

This topic has gone beyond its sell by date and is now about as useful
as QRM.

73 DaveL G3TJP

Tom, N5GE wrote:
I presume you considered that if there was ever a reason to remove the
washer in the future, you may have to damage the front panel to remove
it, and decided that was not an important issue.
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Bob Naumann W5OV

Re: [K3] Assembly question

Exactly what is going on to make this washer rattle? Are you shaking the
radio?

Sorry - I just don't get it.

-----Original Message-----
From: [hidden email]
[mailto:[hidden email]] On Behalf Of David Lankshear
Sent: Wednesday, March 17, 2010 4:38 PM
To: [hidden email]
Subject: Re: [Elecraft] [K3] Assembly question

The fitting of the washer is indeed a trivial matter, Tom. It's on the
inside of the front panel, so if it had to be chiseled off, the marks
wouldn't show and I'm sufficiently competent to use the minimum
amount of adhesive to hold it in place. I won't tighten down the nut
on the front panel beyond finger tight because it would distort the
panel and probably damage the panel coating, besides being quite
unnecessary. A gap of a few thou is irrelevant to the washer's fitting
and function, but a large gap, such as would remain if the washer was
not in place, would potentially stress the DSP board unreasonably, as
pointed out by Don. A rattling washer is a nuisance and stopping that
by whatever means - adhesive, hotmelt, Blu-tak, chewing gum etc. is
a positive contribution to the K3's usability.

This topic has gone beyond its sell by date and is now about as useful
as QRM.

73 DaveL G3TJP

Tom, N5GE wrote:
I presume you considered that if there was ever a reason to remove the
washer in the future, you may have to damage the front panel to remove
it, and decided that was not an important issue.
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Don Wilhelm-4

Re: [K3] Assembly question

Bob,

If the washer is loose, vibration can be created by the internal speaker.
Just squeeze the board up to the front panel and tighten the nut on the
headphone jack - no rattle, no stress when the headphone plug is
removed, !no problem!. It seems some owners are overly concerned about
a small amount of pressure on the board. It is sufficiently flexible to
withstand more stress than you can induce with your fingers and thumb.
OTOH, if there is a large gap (more than a millimeter), you have some
other problem - check to make sure the connectors are plugged correctly.

73,
Don W3FPR

Bob Naumann wrote:
> Exactly what is going on to make this washer rattle? Are you shaking the
> radio?
>
> Sorry - I just don't get it.
>
>
>
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Barry Simpson

Re: [K3] Assembly question

In reply to this post by Mike Reublin

My washer was equally loose so I put an extra one in to fill the gap. Then
it fitted very snug.

Barry VK2BJ

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David Pratt

Re: [K3] Assembly question

In a recent message, Barry Simpson <[hidden email]> writes
>My washer was equally loose so I put an extra one in to fill the gap. Then
>it fitted very snug.

I had no issue with this personally, but as it is a common problem there
would appear to be a need for a compression type spring washer in this
position. FWIW

73
David G4DMP
--
+ - - - - - - - - - - - - - - - - - - - -+
| David M Pratt, Kippax, Leeds, England |
| K1:1117 KX1:0052 K2:1583 XV144 K3:0186 |
+ - - - - - - - - - - - - - - - - - - - -+

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Terry Schieler

Re: [K3] Assembly question

In reply to this post by Bob Naumann W5OV

"Are you shaking the
radio?"

Bob,

Yes. That's exactly what I am doing. When I would flip my K3 over onto its
back or side during initial assembly and subsequent modifications, the sound
of the rattling washer always caused me to stop and check the inside of the
radio for potentially lost hardware, connectors, parts, etc. I always shake
a radio that I've had apart for service. A few times I actually discovered
an errant nut or washer before I reassembled the radio. I spent a lot of
unnecessary time checking for the source of this rattle before coming up
with the hot glue solution. Now, if I shake the radio during reassembly and
hear nothing, I sleep better that night. ;o)

73,
Terry, WØFM

-----Original Message-----
From: Bob Naumann [mailto:[hidden email]]
Sent: Wednesday, March 17, 2010 9:31 PM
To: [hidden email]
Subject: Re: [Elecraft] [K3] Assembly question

Exactly what is going on to make this washer rattle? Are you shaking the
radio?

Sorry - I just don't get it.

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