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"Shortening" a min-module PC board., how to...

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Chris Kimball

"Shortening" a min-module PC board., how to...

I have a BL2 minimodule that's about 1/4" too long for my purposes. I'd
like to cut off a piece of it without zapping the functionality of the
board.

What's the neatest way to do this with commonly available tools and 5
thumb hands?

Thanks,

Chris
WB4WZR
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Jim Wiley-2

Re: "Shortening" a min-module PC board., how to...

Chris -

Several possibilities occur to me:

Assuming you don't remove any portion of any circuit trace (Duh!), I
would suggest an Adel "nibbler". It is designed for metal work,but
works well on circuit boards. It is essentially a hand-powered shear
that removes a small "bite" of material about 1/16" by 1/4" each time it
operates. If used carefully, it can make very precise holes and slots,
and of course shorten material as well. It does require a minimal
amount of clearance to operate. It will accommodate material up to
perhaps 3/32" thick, so circuit board should fit OK.

Lacking that, the next thing I might try is to mount the BL2 on a piece
of scrap wood (as a handle), and VERY carefully and SLOWLY trim away
the excess material using a band saw or jig saw. Keep your fingers well
away from the action, of course. It is important to have something
large enough to grip (the piece of scrap wood) so that if the saw tries
to grab the material, you won't lose control, causing possible injury
and almost certainly ruining your BL2 in the process.

Personally, I would use my milling machine, but not everyone has access
to one of those. However, many model railroad enthusiasts, R/C
airplane pilots, and other hobbyists do have small machines, so ask
around. Your local hobby shop may have some names of people that are
amenable to helping others.

I have done these sort of modifications many times on various boards and
assemblies, and with a little care you can end up with exactly what you
want.

As a last thought - I would stay away from any sort of sheet metal ships
or similar tools around PC boards. In my experience, attempting to use
these types of tools carries a high risk of causing cracks and splits in
the board.

- Jim, KL7CC

Christopher Kimball wrote:

> I have a BL2 minimodule that's about 1/4" too long for my purposes. I'd
> like to cut off a piece of it without zapping the functionality of the
> board.
>
> What's the neatest way to do this with commonly available tools and 5
> thumb hands?
>
> Thanks,
>
> Chris
> WB4WZR
>
>

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David Gilbert

Re: "Shortening" a min-module PC board., how to...

I'm not at all sure I would want to use a nibbler on a populated PV
board. Depending upon the brittleness of the board and how carefully
you are able to wield the nibbler, the resultant mechanical shock could
be tough on some of the components.

I wouldn't try to cut it with a band saw or jig saw either. I don't
think you could clamp the PC board to a larger board uniformly enough to
avoid vibration (and even mechanical resonance from the saw teeth) with
a high degree of confidence.

I think I'd prefer to use a Dremel tool with an abrasive disk to cut the
board. The cutting action would be in line with the board instead of
perpendicular to it.

73,
Dave AB7E

On 5/24/2011 9:22 AM, Jim Wiley wrote:

> Chris -
>
>
> Several possibilities occur to me:
>
>
> Assuming you don't remove any portion of any circuit trace (Duh!), I
> would suggest an Adel "nibbler". It is designed for metal work,but
> works well on circuit boards. It is essentially a hand-powered shear
> that removes a small "bite" of material about 1/16" by 1/4" each time it
> operates. If used carefully, it can make very precise holes and slots,
> and of course shorten material as well. It does require a minimal
> amount of clearance to operate. It will accommodate material up to
> perhaps 3/32" thick, so circuit board should fit OK.
>
>
> Lacking that, the next thing I might try is to mount the BL2 on a piece
> of scrap wood (as a handle), and VERY carefully and SLOWLY trim away
> the excess material using a band saw or jig saw. Keep your fingers well
> away from the action, of course. It is important to have something
> large enough to grip (the piece of scrap wood) so that if the saw tries
> to grab the material, you won't lose control, causing possible injury
> and almost certainly ruining your BL2 in the process.
>
>
> Personally, I would use my milling machine, but not everyone has access
> to one of those. However, many model railroad enthusiasts, R/C
> airplane pilots, and other hobbyists do have small machines, so ask
> around. Your local hobby shop may have some names of people that are
> amenable to helping others.
>
>
> I have done these sort of modifications many times on various boards and
> assemblies, and with a little care you can end up with exactly what you
> want.
>
>
> As a last thought - I would stay away from any sort of sheet metal ships
> or similar tools around PC boards. In my experience, attempting to use
> these types of tools carries a high risk of causing cracks and splits in
> the board.
>
>
> - Jim, KL7CC
>
>
>
> Christopher Kimball wrote:
>> I have a BL2 minimodule that's about 1/4" too long for my purposes. I'd
>> like to cut off a piece of it without zapping the functionality of the
>> board.
>>
>> What's the neatest way to do this with commonly available tools and 5
>> thumb hands?
>>
>> Thanks,
>>
>> Chris
>> WB4WZR
>>

Ken G Kopp

Re: "Shortening" a min-module PC board., how to...

Perhaps a disc or orbital sander would accomplish the task.

DON'T even think of a metal grinder! Any "soft" material
such a PC board debris, brass and especially aluminum
should NEVER come in contact with a grinding wheel.

Why? The soft stuff will be forced into the wheel and can
cause a dangerous "explosion" of the wheel. A common
but dangerous practice.

73! Ken - K0PP

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Merv Schweigert

Re: "Shortening" a min-module PC board., how to...

In reply to this post by Jim Wiley-2

I have also used a dremel tool with the cut off wheel, but also requires
holding the circuit board firmly in something like a vise. Work slowly
and smooth straight cuts can be done.
Wear glasses flying board particles are nasty.
Merv K9FD/KH6

> Chris -
>
>
> Several possibilities occur to me:
>
>
> Assuming you don't remove any portion of any circuit trace (Duh!), I
> would suggest an Adel "nibbler". It is designed for metal work,but
> works well on circuit boards. It is essentially a hand-powered shear
> that removes a small "bite" of material about 1/16" by 1/4" each time it
> operates. If used carefully, it can make very precise holes and slots,
> and of course shorten material as well. It does require a minimal
> amount of clearance to operate. It will accommodate material up to
> perhaps 3/32" thick, so circuit board should fit OK.
>
>
> Lacking that, the next thing I might try is to mount the BL2 on a piece
> of scrap wood (as a handle), and VERY carefully and SLOWLY trim away
> the excess material using a band saw or jig saw. Keep your fingers well
> away from the action, of course. It is important to have something
> large enough to grip (the piece of scrap wood) so that if the saw tries
> to grab the material, you won't lose control, causing possible injury
> and almost certainly ruining your BL2 in the process.
>
>
> Personally, I would use my milling machine, but not everyone has access
> to one of those. However, many model railroad enthusiasts, R/C
> airplane pilots, and other hobbyists do have small machines, so ask
> around. Your local hobby shop may have some names of people that are
> amenable to helping others.
>
>
> I have done these sort of modifications many times on various boards and
> assemblies, and with a little care you can end up with exactly what you
> want.
>
>
> As a last thought - I would stay away from any sort of sheet metal ships
> or similar tools around PC boards. In my experience, attempting to use
> these types of tools carries a high risk of causing cracks and splits in
> the board.
>
>
> - Jim, KL7CC
>
>
>
> Christopher Kimball wrote:
>
>> I have a BL2 minimodule that's about 1/4" too long for my purposes. I'd
>> like to cut off a piece of it without zapping the functionality of the
>> board.
>>
>> What's the neatest way to do this with commonly available tools and 5
>> thumb hands?
>>
>> Thanks,
>>
>> Chris
>> WB4WZR
>>
>>
>>
> ______________________________________________________________
> 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
>
>

Craig Smith

Re: "Shortening" a min-module PC board., how to...

Another option that will work for a straight cut and not subject the pcb to lots of vibration is just a hacksaw.

73. Craig. AC0DS

>
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Peter Wollan-2

Re: "Shortening" a min-module PC board., how to...

In reply to this post by David Gilbert

I'd use a jeweler's hand saw. But then, I have one.

Peter W0LLN

On Tue, May 24, 2011 at 11:53 AM, David Gilbert
<[hidden email]> wrote:

>
> I'm not at all sure I would want to use a nibbler on a populated PV
> board. Depending upon the brittleness of the board and how carefully
> you are able to wield the nibbler, the resultant mechanical shock could
> be tough on some of the components.
>
> I wouldn't try to cut it with a band saw or jig saw either. I don't
> think you could clamp the PC board to a larger board uniformly enough to
> avoid vibration (and even mechanical resonance from the saw teeth) with
> a high degree of confidence.
>
> I think I'd prefer to use a Dremel tool with an abrasive disk to cut the
> board. The cutting action would be in line with the board instead of
> perpendicular to it.
>
> 73,
> Dave AB7E
>

George Danner

Re: "Shortening" a min-module PC board., how to...

I have had success using a belt sander. At work we would slow it down with a
variac; but at home I was just careful and worked slowly.

If there is not too much material to remove then maybe an 8" file would be
effective.

George
AI4VZ

From: Peter
I'd use a jeweler's hand saw. But then, I have one.
Peter W0LLN

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Don Wilhelm-4

Re: "Shortening" a min-module PC board., how to...

In reply to this post by Chris Kimball

Chris,

A disk or belt sander will make short work of that job. Grip the board
tightly with all your thumbs so it does not catch and be flung about the
shop, maybe into a soft spot on your body - be safe.
If you do not have either of those, support the board well and cut with
a hacksaw.
A die grinder will work too.

Be certain you are not cutting into any PC traces on the board unless
you are willing to repair any that are cut off.

73,
Don W3FPR

On 5/24/2011 10:58 AM, Christopher Kimball wrote:
>
> I have a BL2 minimodule that's about 1/4" too long for my purposes. I'd
> like to cut off a piece of it without zapping the functionality of the
> board.
>
> What's the neatest way to do this with commonly available tools and 5
> thumb hands?
>
>
______________________________________________________________
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Home: http://mailman.qth.net/mailman/listinfo/elecraft
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Vic K2VCO

Re: "Shortening" a min-module PC board., how to...

In reply to this post by Chris Kimball

I use a razor saw, or "Zona saw" available at hobby shops (I also like model trains).

On 5/24/2011 7:58 AM, Christopher Kimball wrote:

--
Vic, K2VCO
Fresno CA
http://www.qsl.net/k2vco/
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Matt Zilmer

Re: "Shortening" a min-module PC board., how to...

In reply to this post by Chris Kimball

Use a nibbling tool. Take a tiny amount off of each end.

matt W6NIA

On Tue, 24 May 2011 10:58:31 -0400, you wrote:

>
>
>I have a BL2 minimodule that's about 1/4" too long for my purposes. I'd
>like to cut off a piece of it without zapping the functionality of the
>board.
>
>What's the neatest way to do this with commonly available tools and 5
>thumb hands?
>
>Thanks,
>
>Chris
>WB4WZR
>______________________________________________________________
>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