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This thread has been created to hold the technical documents for Bluecom.


I'll start with the schematic, placement diagram, parts list and Gerber files for the base unit.


Documents for the beltpack will be posted here as soon as they become available.





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The Gerber files for the base unit front and back panels are here. There are three zip files; for the separate panels and a combined layout for both panels. Also, a placement picture and, due to the wonders of laser printer & Pizza-box prototyping, a couple of pictures of the panels in place.









I will be getting five panels made so there will be some for sale in a week or so.


I still have seven base unit bare boards available.

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  • 4 weeks later...

Here are the 1.0 release Gerbers for the Power Unit panels. I have modified the solder mask layer so that the text and graphics will now be plated. There are three files; two are for separate front and back panels and the third is for combined panels. The combined panels file has both a silkscreen layer and a V-groove layer. If your PCB manufacturer can rout a 0.9mm wide v-groove then use the latter otherwise use the silkscreen layer and separate the panels with a hacksaw and fine file.







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  • 3 weeks later...

Here are the technical documents for the Bluecom Beltpack:







Component placement:





Parts list:





Gerber files:





Front and back panels are currently being laid out and will be available here in a couple of weeks once prototype boards have been received and fitted.

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  • 2 weeks later...
  • 2 weeks later...
  • 1 month later...

... and finally here is a zip file of all the documentation for the Bluecom project. Sorry that it's taken so long to complete this, but there have been a number of unforeseen interruptions in the process. I hope someone will go through everything and check that it's all OK. I've been looking at it for so long now that I don't see the errors any more!


All of the designs are done in Easy PC version 17. If anyone would like copies of the design files for this project please contact me off-list.


Have fun.



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  • 7 months later...

They are two layer boards with top and bottom solder masks and top silk screen. The dimensions are 3.95 inches by 3.13 inches or in modern money 100.33 mm by 79.5mm.


If you tell the manufacturer it's 100mm by 80mm, they'll be happy enough, but if you say it's over 100mm you might go into the next price bracket.

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  • 2 weeks later...

Thanks to BR member 'pmiller056' for producing a set of drawings and instructions for making laminated paper panels for the Bluecom beltpack. The zip file is attached and here are the instructions:


I have chosen to make the front and rear panels in a different way from the original design. In the attached zip file there

are 4 photos showing the finished panels, 4 pdf files for printing and 2 original source files in svg format. The svg files

are editable with 'inkscape' which is a free download (gpl licence). If you are printing from the pdf's make sure that all

print scaling is turned off. All dimensions have been taken from the original gerber files and are in inches. Do not solder

the 'Call' pushbutton to the PCB until the panel is made - the pushbutton is not a firm fit in the PCB and is easily

soldered into a place where it does not go through the panel hole correctly.


Cut the 'drilling' images to the outer border and stick them onto the blank panels with spray-on glue. Note that the specified

box has slightly asymmetric panels. Photo mounting spray glue works well, carpet tile glue can be hard to use tidily. Use

this as a template for cutting and drilling holes. Taping the print to the panel edges instead of glueing will not work

accurately as the paper will distort when holes are drilled and filed through it. After the panel has had all the holes cut,

remove all the paper and glue residue with a suitable solvent.


Print the 'Finished' images onto a slightly grey coloured paper and cut to the border. Laminate the cut images in an office

laminating machine using a matt finish pouch. Cut the laminated prints down to slightly smaller (1-2mm) than the blank

panel size but leaving the paper sealed so that the edges and corners don't catch and peel. Stick these cut down

laminated prints with spray-on glue to the cut and drilled blank panels. Where holes are required, cut through the

laminated paper with a sharp scalpel or similar. Assemble the panels and complete your good-looking project.


This process can be used for other home made projects and produces durable, good looking panels. If there is a bezel

or other means of hiding the panel edge, then the laminated print can be cut to the panel edges. As can be seen from

the photos I've chosen to omit the front panel jack socket and use an alternative headset connector to suit my

application. Edit the svg files provided using 'inkscape' for your own purposes.


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  • 4 weeks later...

In order that the problems with the four-pole jack are resolved, I have modified the schematic and the PCB to version 1.3. The four-pole jack is now only connected to a 4-pin 0.1" header situated between the jack socket and the headset gain control. This leaves the constructor plenty of leeway to connect the jack socket however they wish. If large DC blocking capacitors are required they can be mounted between the 8-pin KK connector and the 4-pin header.


Nothing else has changed in the schematic or the layout so it should all work OK, but I must emphasise that it hasn't been tested.


Have fun.




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