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New PCB Design for Intellivision installs - Sample install pics



I already made a blog post not that long about about my new designs and had posted pics of the render of the PCBs. Well, I actually received the PCBs in the other day and have had a chance to test them out. While I did make a pretty big blunder on my model 2 specific PCB, it was easily fixed and isn't that big a deal to fix in situ when installing. And it only affects me since the gerbers that I play to release publicly already have the fix in place so future boards that get made up should be good to go.

A quick recap on these PCBs. It is a total of 3 different boards. The bottom base PCB is the same for both original 2609 model and INTV 2 model consoles. I designed it that on purpose. So what is different between the models is the top PCB that you use as they are specific to the model of the console you plan to use them in. These mounts are designed to be installed in place of the RF modulator so that a 'No Cut' option is able to be achieved when upgrading your Intellivision.

Here is a mock up the 2 PCBs put together for the original 2609 model of the console. This is essentially an upgraded extension of my original older mounts that is easier to install and secure into place vs the older mount PCBs I've been using. The top PCB has a large solder section on it so that the mini din jack that is used can be more easily be quick tack soldered into place to test alignment and fit before flood soldering all around the jack to secure it into place. While the mini din is technically being installed upside down in this fashion, it is important to know that the actual 2609 style mainboards install upside down to begin with. As a result, the mini din is actually right side up in the end.





The model 2 setup was much more difficult for me to design and I really gave my calipers a workout making so many measurements. So the main difference with the INTV 2 setup is that the bottom base mount PCB (Again it is the same on both models), has cut outs on one corner of it. This is because the top board of the INTV 2 mount actually has you solder the mini din direct to the PCB like it would be normally. The cutouts on the bottom base PCB allow for room for these soldered pins off the mini din to come through and allow the two PCBs to sit flush together. It does require that the pins and ground tabs be clipped fairly flush to the PCB once soldered to make sure nothing sticks out beyond the bottom PCB where it would likely then short on the large ground plane that the RF modulator was sitting on. But this isn't a big deal and the end result is a nice finished mount where the mini din is again able to be right side up when all put together. Previously, the mini din was actually upside down on the INTV 2 installs. So this will be less confusing for people going forward.

Here is a detail showing the two sections assembled. You can see the cutouts on the bottom base PCB to allow for the soldered pins of the mini din to come through. So this means that you need to solder the mini din to the top PCB first.


When you cut the soldered connections pretty flush to the PCB the mini din was soldered to, it will ensure that the soldered connections and pins don't come through to cause any issues below. Here you can see where I trimmed an applied fresh heat to the joints after to be sure everything was secure and wouldn't cause any issues with shorts.


Like mentioned before, the entire PCB assembly is designed to install in place of where the RF modulator was located. Here you can see how that would look internally. There are solder pads provided on the PCB for all the needed connections. There are 2 sets of RGB pads that are to be used depending on if you use the 8-pin or 9-pin part of the PCB. Yes, I designed it with through holes for both types of commonly used mini dins for RGB installs like this. There are 3 pas in the center that are shared between both mini dins. Those are the +5, Sync, and Audio. In the picture below I used an 8-pin mini din. So you can see the space in the opposite corner for the 9-pin through holes that weren't used in this install. You can also see the pads specific for the 9-pin that weren't used. The blob of solder on the mini din is part of what I have to correct for on these first set of PCBs but won't be needed on future ones.


And once in place, it should be centered pretty well in the spot where the RF used to be allowing for plenty of room for your cables to be plugged in without any modification of the case. Again, a 'No Cut' option is achieved. Ignore the switch below this as that is needed for something else since this INTV 2 uses an older RGB setup.



So again, the plan is to release the gerbers for these publicly so others can have them made up for their own installs. I've already had a few other modders reach out to me wanting the gerbers because they actually want to change out their current mounting to use of these new setups. 

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