Thursday 1 December 2016

Bitx40 V3 Radio Page

Bitx40 V3  -   Home Brewed enclosure and DDS VFO


BitX40 V3 -  A wonderful design with excellent performance.  Thanks a lot to Farhan for providing this to HAM fraternity.

This assembled board gives no further scope to do much for an average home brewer.  A suitable enclosure is some thing needed - one with a compact size.
 
I tried in SP Road, Bangalore for it but nothing was available that suites well.  I was not ready to give up and finally returned home with 4 square feet of 1.6mm Aluminium sheet.  Idea was to give a try to make an enclosure of size similar to that of FT817.

I realized soon that sheet metal work is not that easy, without any proper tools. I just had a few usual tools  - drill, callipers, file and some sand paper. That's it. 
 
First, I cut the sheet to the required sizes after careful measurements. Used the callipers to measure and marked the lines to cut.  Fixed the steel scale and tightened with small wises. Then started making groove along the line where I want to cut it. When the groove became bit deeper, I placed the sheet along with a sharp edge ( used the edge of the drawer ) and carefully bend the sheet both directions. The sheet was able to cut and did a little bit of filing to smoothen the edge.






 
Aluminium sheet bending was one of the big challenge. This also done with making a groove - but if the groove is more deeper then the sheet may start breaking. If the groove is less then it will be difficult to get the bend properly.  After carefully bend to close to 90 degrees, then used a flat wooden piece, tap slowly to bring the bend to 90 degree.








Added  DDS VFO with Arduino nano and AD9850 module.

Look at now..







 73s
Sajeesh Pilakkat
VU3PSZ
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15 comments:

  1. Adi Ramesh2 December 2016 at 09:08

    Beautifull sajeesh true homebrew.......

    ReplyDelete
  2. Adi Ramesh2 December 2016 at 09:08

    Beautifull sajeesh true homebrew.......

    ReplyDelete
  3. Sajeesh Pilakkat7 December 2016 at 01:05

    Thanks Ramesh.. It came out much better that I thought.

    ReplyDelete
  4. sarma12 February 2017 at 20:50

    WoW sajeesh jee. The best of fabrication ability shown.
    Can i be lucky to have one from you?

    please tell me the formalities.
    regards
    sarma
    mvssarma@gmail.com

    ReplyDelete
  5. Sajeesh Pilakkat13 February 2017 at 05:15

    Thanks for your compliments Sir,. I don't have any tools other that you see in pictures. It was so tedious and time consuming to do this with no tools. I will be happy to guide you in case you opt to fabricate one self.

    ReplyDelete
  6. FastVoteFred13 February 2017 at 09:52

    Hello Sajeesh, Your hand made aluminum case is beautiful to look at and makes the Bitx40 radio look very professionally done. Be proud of this case you made from minimal tools. Do you have any hand made drawings for your Bitx40 Aluminum case that you can take a picture of and share here on your new blog? I am looking for dimensions on the size of the cut aluminum sheets and the fold lines/grooves that you inscribed to bend the aluminum sheet into a "U" shape.
    Also, could you compare the hole sizes listed below for the components with the hole sizes you drilled and filed into the rear and front panels.

    What type and length of screws did you use to hold the case together and hold the front panel?

    Can you measure and make a list of dimensions for your 4 aluminum pieces to this case so that others can duplicate what you have created? I would like to create 2D drawings using http://Librecad.org Free Open Source Software with your help Sajeesh.

    Here is my posts on the Bitx20 group about making a Metal Enclosure.

    https://groups.io/g/BITX20/topic/creating_a_metal_enclosure/4314170?p=,,,20,0,0,0::Relevance,,enclosure,20,2,0,4314170
    https://groups.io/g/BITX20/topic/creating_a_metal_enclosure/4314155?p=,,,20,0,0,0::Relevance,,enclosure,20,2,0,4314155

    Richard Andrew Knack
    Feb 3 #21402

    For the parts that come with the kit (these are actual, measured part diameters - adjust your holes for clearance):

    Volume potentiometer: 6.80 mm

    Tuning potentiometer: 9.65 mm

    Stereo jacks (for mic and headphones): 5.86 mm

    Power jack: 12.31 mm

    BNC connector: 9.2 mm

    SO-239 UHF connector: see drawing 0.641 Inch center hole. 4 concentric 0.125 Inch holes, 1.016 inch center to center, 0.718 center to center vertically
    0.5077 at 45 degrees

    Hope this helps!

    Rich
    KC8MWG


    Sajeesh, I created a folder to put pictures and drawings in for you Aluminum case.
    https://groups.io/g/BITX20/files/Enclosures_Metal_or_Plastic/Metal_Box_files/vu3psz_Aluminum_Case

    With your help, we can create 2D using LibreCAD software.

    I am proud of your efforts to make a beautiful case, Sajeesh. I hope to work you on the air oneday via amateur radio. 73's
    Fred Finster WB7ODY

    ReplyDelete
    Replies
    1. Sajeesh Pilakkat15 February 2017 at 21:16

      Thanks Fred, Really appreciate your comments. It is really encouraging. As of now i don't have any drawing or measurement details. I will soon update the page with details. Thank you..

      Delete
  7. FastVoteFred13 February 2017 at 11:35

    Here is another Farhan designed radio
    https://sites.google.com/site/ae5phradionotebook/minima_main_page

    Have you built an RF probe to measure RF signals? Like the N5ESE Ballpoint design.

    http://www.norcalqrp.org/KI6DSrfprobe.htm
    http://www.n5ese.com/rfprobe2.htm
    http://www.n5ese.com/rfprobe1.htm
    https://sites.google.com/site/ae5phradionotebook/home/homebrew-projects/n5ese-ballpoint-rf-probe

    Sageesh,share what it is like to operate amateur radio on 40 meter Single Side Band in India. Do you make many contacts local or long distance inside India?

    I read about the hardships VU3INJ went through trying to become an operating amateur radio operator.
    http://vu3inj.blogspot.in
    I hope the Bitx40 makes it affordable for many other Indians to get on the air as amateur radio operators. Your blog here, shows how to build a case by hand.

    Is there any activity on the 50 Mhz, 6 Meter band inside India? I am assuming that very few radio equipment exists to make contacts on SSB in India. I would like to see a modification to make the Bitx40 operate at 50-52 Mhz. I realize that most contacts on 6 meters would be in a 20 kilometer radius for local contacts unless the band was open.

    Sajeesh, your thoughts?

    Fred Finster wb7ody
    wb7odyfred@yahoo.com

    ReplyDelete
    Replies
    1. Sajeesh Pilakkat15 February 2017 at 21:32

      I haven't made any permanent RF probe yet. But makes temporary one when ever needed :)..

      Most of the HAMS here operates on 40mts where majority of activities, but there are many who operates DX on 20mts.

      Unlike earlier, now the availability and accessibility of Commercial equipment's are good in India- Most of them are imported. However Bixt40 has created more accessible for new comers too.

      As far as I know, 50Mhz and 6 meter are very limited here

      Delete
  8. FastVoteFred19 February 2017 at 22:09

    Well let us hope the Bitx40 from http://www.hfsigs.com increases the number of Indians who become amateur radio operators and enjoy building radios and talking with fellow hams on 40 meters. So happy to see the photos you shared, Sajeesh. Waiting for any minimal notes on hole sizes and x,y locations from edge of the case. Sizes of the aluminum pieces cut from sheet before being bent into shape. The bend locations (fold lines) in the metal.

    Interesting DIY radio projects. I liked the VHF DRA-818 transceiver. You can build a nice case for this 1 watt radio, Sajeesh. You have experience now.
    https://www.sv1afn.com/shop.html
    https://www.sv1afn.com/projects.html
    https://www.sv1afn.com/dra818.html VHF 2meter and UHF 70 centimeter Transceivers.


    Sajeesh, is it wild impossible dream to purchase a CNC Plasma metal cutter from China and set up your own business of making aluminum or stainless steel metal enclosures?

    http://www.alibaba.com/trade/search?fsb=y&IndexArea=product_en&CatId=100008474&SearchText=cnc+plasma+cutting+machine

    http://www.reach3dprinters.com/ A 3d printer
    https://www.facebook.com/Reach3DPrinters

    Your thoughts, Sajeesh?

    ReplyDelete
  9. FastVoteFred20 February 2017 at 00:01

    Reach 3D Printers
    All-in-one 3D Printer, Laser Cutter, Engraver and Milling Machine Interesting photos, videos, and sharing of ideas and upgrades to the Reach 3D Printer

    https://plus.google.com/u/0/communities/117771940868613599658

    ReplyDelete
  10. FastVoteFred27 February 2017 at 00:11

    Any simple measurements performed yet? I would like to make a http://librecad.org CAD DXF drawing based on your measurements.

    Here is what I have for notes in a text file.

    For the parts that come with the kit (these are actual, measured part diameters - adjust your holes for clearance):

    Volume potentiometer: 6.80 mm 0.2677 Inches 17/64 Inches Fraction radius 0.1340

    Tuning potentiometer: 9.65 mm 0.3799 Inches 3/8 Inches Fraction radius 0.1900

    Stereo jacks (for mic and headphones): 5.86 mm 0.2307 Inches 15/64 inches Fraction radius 0.1154

    Power jack: 12.31 mm 0.4846 Inches 31/64 Inches Fraction radius 0.2423

    BNC connector: 9.2 mm 0.3622 Inches 23/64 Inches Fraction radius 0.1811

    http://www.rapidtables.com/convert/length/mm-to-inch.htm Website used for conversion

    SO-239 UHF Connector 0.641 inches surounded by 4 0.1250 (1/8 inch) holes separated by 0.718 inches on center, equi-distant around the central 0.641 hole. 1.016 across center to center for 0.125 holes or 0.5077 at 45 degress.

    Audio Volume Control with antirotation tab. From Mouser Catalog reference a Bourns Potentiometer
    http://www.mouser.com/ds/2/54/85126-776477.pdf
    Does this offset of .375 inch (9.53mm) and hole size 0.125 inch (3.18 mm) and tab width of 0.105 Inch (2.67 mm) ??

    The central shaft diameter hole size is 0.390 inch (9.91 mm)

    https://groups.io/g/BITX20/files/Enclosures_Metal_or_Plastic/Metal_Box_files/vu2xes_Aluminum_Case
    http://bitxhacks.blogspot.com/2017/02/vu2xes-cad-files-for-bitx-box.html
    Bitx40v3 PCB holes layout pattern.
    4 Holes sized 3.5 mm Diameter, 1.75 Milimeters radius, in a 115 mm x 117.5 mm rectangular pattern for the Bitx40v3 Printed Circuit board mounting holes. Front to Back 117.5 mm , Left to Right 115 mm
    Holes offset from left edge of metal about 21.2 mm in Vu2xes aluminum box overal layout of 299 mm length front to back, 160 mm width left to right, 9.8 mm tabs on left and right sides.

    ReplyDelete
    Replies
    1. Sajeesh Pilakkat1 March 2017 at 08:10

      Basic measurements are added in next page ( see below link)http://vu3psz.blogspot.in/2017/02/bitx40-enclosure-measurement-and-more.html

      Hope this helps

      Delete
  11. ARNAB SEN ( VU2CMV )14 July 2017 at 19:54

    Great homebrew indeed !!

    ReplyDelete
  12. ig venu14 July 2017 at 22:43

    Excellent workmanship will wood work casing workout in which a simple carpenter can easily manage. Best regards ivg

    ReplyDelete

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