As many Atari 5200 owners have learned, the game cartridges produced by Activision for the 5200 can be very problematic. They tend to exhibit certain characteristic issues, mostly related to age and how it has affected the printed circuit boards that Activision used.
First, the card edge fingers seem more susceptible to corrosion than in most cartridges, possibly due in part to the lack of a dust cover like Atari's cartridges had. Second, the board itself seems to have been made just a bit too short, so it doesn't sit in the cartridge port as deeply as it should. Only the tips of the fingers (which would wear out first) ever make contact with the connector pins inside the port; as both the cartridge and the port get dirty over time, it doesn't take much dirt to prevent good contact. As a result, you really have to scrub these boards clean to get a good, reliable connection, and I find that they often require regular cleaning thereafter.
For a long time, I've been intending to remedy these problems in my own cartridges by designing a new replacement PCB that fits inside Activision's 5200 cartridge shells. Earlier this year, I finally found the time to do it. Here is the result:
This board is compatible with non-bankswitched Atari 5200 games up to 32K in size, so it can be used to repair or restore any of Activision's 5200 cartridges to working condition. Just burn the game binary to an EPROM, install it on the board with a 74LS08 logic chip and a 0.1uF decoupling capacitor, and drop it into your original Activision cartridge shell in place of the original board!
(In Activision's cartridges, the chips face the *back* of the console when the cartridge is inserted, so remember this if you wish to test your assembled board outside of its shell. The board itself is keyed, so it can only be mounted inside the shell in the correct way.)
To keep the assembly as simple as possible, this board is designed specifically for use with a 32K EPROM (27C256). If the game you wish to repair is smaller than 32K—as I believe all of Activision's released 5200 games were—simply concatenate enough copies of the binary to fill the ROM. (I do not provide or burn the EPROMs, so this step is up to you.) Of course, you can also use non-Activision game binaries with this board if you wish, as long as they are 32K in size or less.
So, if you have any dead or intermittent Activision 5200 cartridges in your collection that you'd like to rebuild, just send me a PM and I'd be glad to supply you with the boards to do it! Here are the prices, with a discount offered for bulk purchases:
1–9 boards: $4.00 each
10–49 boards: $3.50 each
50–99 boards: $3.25 each
100+ boards: $3.00 each
(Postage will be extra. If you also need a 74LS08 and capacitor for your board(s), I can supply those as well, for an additional $0.50 per board.)