Ramsey Electronics PG13 Instruction Manual page 22

41. Place the metal ball terminal in whatever holder you've chosen. Heat
a spot on the ball with your soldering iron and hold solder on it until the
ball is hot enough to melt the solder. Once you have a good size blob of
melted solder on the ball, take the nail and place the head of the nail in
the blob of solder. (No, you don't need three hands; simply use the hand
that was holding the solder to hold the nail!) You'll want to hold the nail
with needle nose pliers, as it may become hot. When you can tell that the
nail is solidly connected (it might still move but you can see that the solder
is melted around it enough that it will hold when it cools) you can take the
soldering iron away. The fun part is holding still until the solder cools. You
can blow on the connection to hurry things along but try to be patient and
not move things around too much. You want the ball solidly attached to
the nail. Set the ball and nail aside to cool while you do the next step.
Note: If the ball is dislodged and falls, please don't try to catch it or move it
with your bare hands! If it is hot enough that solder will melt on it, trust us
when we say it is extremely hot and will burn you if you come in contact with it.
Use the utmost caution on this step and grab the emergency oven mitt if
needed!
42. Looking at the transformer you'll see that it has a wire coming out of it.
Cut the wire so that it easily reaches the post with some slack. Strip back
the wire 1/4 of an inch, and tin.
43. If the ball/nail combo is cool, place the nail in the plastic post so that
you can see how far in it will go. Now take it back out. Wasn't that fun?
44. Solder the wire stripped in step 41 onto the nail with the ball on top.
You can wrap the wire around the nail to hold it in place while you solder
it. You'll want to solder it toward the end that will be placed in the plastic
post, (see, that's why we sized it up in the last step!) otherwise the ball will
soak up all the heat and you'll have a hard time soldering the wire on.
45. Place the cooled ball/nail/wire assembly in the hole in the plastic post.
46. Install J1, the three terminal connector. Make sure the wire access
holes face to the outside of the board.
Final Check
Well, I hope you're not too disappointed that there were only 46 assembly
steps but at least we will have a lot of time left to do some cool experiments!
Before we go too far, we need to check back over our work to make sure we
didn't make any mistakes. Even people who really know what they are doing
will occasionally make a serious mistake, and we don't want that here.
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