SI 5066 PG 7

Sonic Impact 5066 Amplifier Upgrade - Page 7 of 10

De-soldering and soldering small components required a more purpose-built tool than the old Craftsman soldering iron. Based on good things I'd read on various forums, I decided to purchase a a nice soldering unit from Circuit Specialists Inc.;

CSI-Station 1 ($34.95)
SMD Hot Tweezer Adapter, CSITWZ-Station ($29.00)
1 mm single flat 40^o tip, KD-M-1C ($4.95)
long conical fine point tip, KD-M-LB ($4.95)
3.2 mm chisel tip, KD-M-3.2D ($4.95)
digital multimeter, 9300G (FREE with CSI's promotional internet offer!)

This is the unit that I will use to perform the remainder of the surgery on the SI 5066 amplifier.

Now that I was getting close to having the amp fully disassembled, it was time to start selecting components so that I could do a layout drawing and choose a suitable enclosure size.

Here's a list of the components that I purchased:
(prices in U.S. dollars)

Item Description	Price (ea)	Qty	Tax & Shipping	Total
Sonic Impact 5066	24.98	1	2.06	27.04
Potentiometer, Radio Shack # 271-1732C	3.29	1	0.27	3.56
Knob,1" knurled Radio Shack # 274-424 (pkg. of 2)	2.99	1	0.25	3.24
Jack, power, female, 2.5 mm, panel mount, nickel-plated, Radio Shack # 274-1576	2.59	2	0.43	5.61
Plug, Power, male 2.5 mm, nickel-plated, Radio Shack # 274-1573	2.59	1 pr	0.21	2.80
Enclosure, aluminum, 3.9" x 10" x 7.3", Hammond # 1402H	44.48	1	8.77	53.25
Jack, RCA, female, insulated, panel mount, gold-plated Cardas CTFA, Handmade Electronics # 5-0006R	4.25	1	2.57	6.82
Jack, RCA, female, insulated, panel mount, gold-plated Cardas CTFA, Handmade Electronics # 5-0006W	4.25	1	2.57	6.82
Posts, binding, insulated, panel-mount, gold-plated brass, Handmade Electronics # 5-21050	3.98	1 pr	2.56	6.54
Switch, toggle, SPDT, panel-mount, Radio Shack # 275-603, 5A @ 120 VAC	2.29	2	0.38	4.96
LED, orange, panel-mount, 12 VDC, 12 mA, 110 mcd, Radio Shack # 276-272	1.99	1	0.14	2.13
LED, green, panel-mount, 12 VDC, 12 mA, 100 mcd, Radio Shack # 276-271	1.99	2	.29	4.27
Battery, SLA, 12 VDC, 3.4Ah, Battery Mart # SLA-12V3-4	7.95	1	3.40	11.35
Charger, 12 VDC, 500 mA, Battery Mart # ACC-12BC0500D-1	9.95	1	3.40	13.35
Screw, machine, pan hd, #6-32 x 3/4" lg, brass	0.87	4	0.07	0.94
Washer, flat, #6, brass	0.83	8	0.07	0.90
Nut, hex, #6-32, brass	0.83	4	0.07	0.90
Tip, door stop, rubber, National # N225-565 V236T	1.20	4	0.10	1.30
Total				155.78

SOME DETAILED SPECIFICATIONS:

Potentiometer

Make: Alps
Model: Alps RK27112A-S25-C0-A104 (?) = (RS # 271-1732C)
Markings: 150G 100KAX2
Overall maximum resistance: 100 kΩ ⁺/- 20% tolerance
Rated power: 0.05 w
Maximum attenuation: 100 dB
Total rotation: 300^o ⁺/- 3^oMounting: panel-mount in ⁵/₁₆" hole with supplied hex nut & flat washer
Shaft diameter: 6 mm
Terminals: 4, 1-2 = input, 1-3 = output, 4 = 40% loudness tap
Manual Soldering: 350 C (662 F) within 3 sec or less

Battery

Make: Battery Mart
Model: SLA-12V-3-4
Type: Sealed lead acid
Nominal Voltage: 12 VDC
Rating 3.4 AH
Terminals: F1 (0.187" x 0.032" solder lug/quick disconnect)

Charger

Make: Battery Mart (Universal Battery Corporation)
Model: # ACC-12BC0500D-1
Type: Dual Voltage, Regulated SLA Battery Charger
Primary: 120 VAC (+/1 15V) 60 Hz
Exciting Current 45 mA
Rated input power: 14 VA
DC Resistance: 82 Ohm +/- 10%
Fast Charge Output: 14.8-15 VDC @ regulated 500 mA
Float Charge Output: 13.6-13.8 VDC @ 30 mA
Insulation Resistance Primary-Secondary: 100 M Ohm @ 500 VDC
Insulation Resistance Primary-Core: 100 M Ohm @ 500 VDC
Dielectric Strength Primary-Secondary: 1500 VAC for 1 minute
Dielectric Strength Primary-Core: 1500 VAC for 1 minute
Dielectric Strength Secondary-Core: 1500 VAC for 1 minute
Max. Temperature Rise: 75 C @ rated load

I drew all components to scale in Microsoft VISIO and designed a plan, front panel and rear panel layout.

Enclosure Plan View

Front Panel View

Rear Panel View