Pedal PCB Crackle Jack (Zvex SHO w/ vol control) in a 1590G

I took a bunch of pics for this one so you can see my build process.

I started by trimming the poles on the switch to half height, then put the switch in the enclosure and solder the daughter board, and begin populating it. Then comes a back and forth dance of installing and removing parts temporarily to get wire lengths correct and make sure it’s assembled in the right order.

I mounted the pot on the front side of the board and bent it over to make the board fit in the enclosure. I also had to trim one of the corners, luckily there weren’t any traces in that corner. There was an electrolytic pot which I was able to mount sideways and at such an angle to fit perfectly under the legs of the pot. After messing with its alignment I reflowed its solder to correct any breaks that may have happened. I also checked continuity to the board and all was good.

I use hot glue to hold the LED. I tin every wire and use flux when I need the solder to take quickly. I had to off mount one of the pots and there are a ton of wires so I had to map them out in a way that makes it easy to remove the board for any future troubleshooting.

Soldering the power jack was fun bc the wire is in a super cramped area and faces away from me. Yay. I made a hook for the wires that connect to the off board pot so that they would stay in place while soldering.

I spaced the audio jacks away from the ceiling of the enclosure so there would be room to run wires above them. These jacks have a 45 degree notch on one side and I orient them so that the 3mm LED fits in the space made up by their notches. This also gives room for the amp jewel to screw in. To get that to work I tap its hole with a specialty tap that fits the jewels’ weird ultra fine thread pitch.

I test it and it works! (The LED stays on faintly with power removed but it sounds good so I’m leaving it!) then its time to put on the knobs and call it a day.

Last pic are some other 1590G projects I’ve done. I think I’m good for a while with those. My next few pedals are going to be in 1590bb’s and that will be a nice change.