The Martone Assembly Work Instructions

Pre-Assembly Instructions:

● Please check that all parts and hardware are included before beginning each assembly. ● Save all packing materials until assembly is complete to avoid accidentally discarding smaller parts or hardware. ● Read through the preparation and assembly instructions in full before beginning assembly. ● Please use CAUTION AND CARE WHEN LIFTING the product to avoid personal injury and (or) damage to the product.

Hardware Required: See BOM for reference as needed and for full list of electrical parts. Part Number Material/Item Qty./Size

9062K21 1"DIA Aluminum Rod 2ft 1

- 5th String Banjo Friction Peg 4

- 5th String Peghole Reamer 1

- Acrylic Sealer 1

92942A703 PCB screws 1

7237T81 Brush for gluing small parts 1

94459A380 Leg Heat-Set Inserts 4

91792A540 Leg Screws 1

93121A335 Leg Screw Posts 2

89965K371 Leg Tube (3ft) 2

- Leg/Cover Plates wood sheets 2

- Magnets 4

- Metal Press fit Dowels 93365A220 PCB Heat-Set Inserts 8

93802A221 PCB Screws 8

85585K102 Polycarbonate 1

- Screw Post Barrels for TS 8

- Screw Post Screws for TS 8

97155A426 Screw posts for legs 2 3

- Screws (CNC table) 2

497-SP400816-1 Speakers 2

Speaker Grill 1

1370N53 Thick Rubber 2

1370N51 Thin Rubber 1

- Wood Glue 1

- Wood Stain 1

- Wood Stock 6/4" x 8.25" x 9ft (Poplar) 1

Tools Required:

Tools Qty.

5th String Peghole Reamer 1

Brush for gluing small parts 1

Flat-head screwdriver 1

Phillips-head screwdriver 1

Round nosed soldering iron 1

Sharp nosed soldering iron 1 120-400 grit sandpaper 1 Clamp 1 Needle Nose Pliers 1

Machines Required:

Machines

CNC Router

Drill Press

Planer

Panel Saw

Band Saw 4

Files Required:

Assembly Files

Part File Name Locations

Tuner Insert Tuner Insert.stl Edge | Google Drive

Bridge Insert Bridge Insert.stl Edge | Google Drive

Magnet and Dowel Insert Magnet and Dowel Insert.stl Edge | Google Drive

Speaker and Leg Insert Speaker and Leg Insert.stl Edge | Google Drive

Battery Insert Bracket Battery Insert Bracket.stl Edge | Google Drive

Battery Insert Battery Insert.stl Edge | Google Drive

PCB Insert PCB Insert.stl Edge | Google Drive

Leg Tube Leg Tube Drawing.pdf Edge | Google Drive

Tripod Leg Holder Tripod Leg Holder Drawing.pdf Edge | Google Drive

Tuner Cover Plate Tuner Cover Plate Drawing.pdf Edge | Google Drive

Non-Tuner Cover Pate Non Tuner Cover Plate Drawing.pdf Edge | Google Drive

Nameplate Martone Nameplate Drawing.pdf Edge | Google Drive

CNC Design Outline CNC Design Outline Martone Edge | Google Drive

CNC Stock Locator Holes Martone_Dowel_Drill01.step Edge | Google Drive

Lower Frame Martone_Low_Frame01.step Edge | Google Drive

Upper Frame Martone_Up_Frame01.step Edge | Google Drive

Assembly Instructions:

3D Printed Parts Print the following parts (left to right in Figure 1): ● 1 x Tuner Insert ● 1 x Bridge Insert ● 2 x Magnet and Dowel Insert ● 2 x Speaker and Leg Insert 5

● 2 x Battery Insert Bracket ● 1 x Battery Insert ● 1 x PCB Insert

Figure 1: Print Orientation

Print parts with flat faces down for best results. Let the printing bed cool after printing before removing for the least chance of deformation. Remove any support material by hand (typically crosshatched supports). If any support material is difficult to remove, cutaway with an exacto knife. If imperfections cause issues with fit or assembly, reprint or sand/file away imperfections. 6

Figure 2: Heat Set Inserts and 3D Prints

Figure 3: Small Parts Orientation and Placement 7

1. Prepare the work station with heat set inserts, 3d printed parts, clamps, lighting, soldering irons, needle nose pliers, ventilation, and any flat part laying around. 2. Heat up soldering iron. 3. Clamp 3D printed part to table. 4. Hold the heat set insert with pliers and place gently over hole location. 5. Push gently down with soldering iron until the insert is 70% down into the hole. 6. Push down on insert with a flat surface until it comes parallel to the 3d printed part’s surface. 7. Repeat for all heat set inserts. 8. Use sharp nosed soldering iron for small tapered inserts and round nosed soldering iron for the larger heat set inserts for the leg/speaker part.

Prepare the work station with super glue, small brush, plastic dowels, and magnets. Brush super glue on magnets and place them in magnet recesses. Brush super glue on the dowel and place it in plastic dowel recess. Wipe off any glue that got on unwanted surfaces-- if necessary sand it off.

Wood Touchscreen Cover Plates Cut Tuner Cover Plate, Non-Tuner Cover Plate, and Martone Nameplate to size with band saw. Drill holes in both plates with drill plates at locations per their corresponding drawing prints.

Wooden Frame With a band saw cut the 8ft Poplar Board into 3 sections such that none is less than 33” in length. Plane these boards down to 1” thickness. Rip these boards down the middle such that neither board is less than 4” in width and as close to 4” as possible in width. With a band saw, cut the boards to 33” in length.

Zero CNC router to table height and place at desired location for press-fit dowels to hold the Martone. See CNC Design Outline for notes on how to design toolpaths for Martone Frames. Run the dowel_hole_drill.file. Vacuum up dust and hammer in metal ⅜” dowels into the three holes created such that they are vertical.

Line up 33” x 1” x 4” board as best possible to xy plane. Hand drill a hole at each end near the short edge then screw down the board until it is secured to the CNC Router table. Be sure that the board is running perpendicular to the xy plane. This is very important for the frame to align and wall thicknesses to be correct. Run the Martone_hole_drill.file. Vacuum up dust and remove screws. Check the fit of the board onto the recently placed dowels. The frame should be able to slide in and out of the dowels but also remain securely in place at the bottom of the 8 dowels when subject to x-y force. Any shifting will cause wall thicknesses to be too thin on the frame. Repeat these steps for the next board (other half of the frame). Do not reuse the same screw holes on the router table for accuracy.

Place one of the boards with holes drilled on the dowels. Zero the x y and z coordinates to the top left corner. Run Martone_Upper_Frame.file. When milling stops, flip the part on its long side, place 3D printed dampers, and resume. Dampers are not necessary but were made in case rattling became an issue. Remove the frame from the dowels. Repeat the same steps with the next board and Martone_Lower_Frame.file.

With a band saw or table saw chop the tabs from the ends of the Martone frame. Sand the Martone elliptical surface until smooth.

Drill holes in Martone at appropriate locations for touchscreen screwpost holes, tuner holes, and Tuner pre-ream holes using 3D print hole guider. To locate hole locations, many options are available. First option is to take the lasered polycarbonate sheet and fasten over the Martone frame. Draw in circles where holes are to be drilled. This will allow holes to line up with polycarbonate well if securing is done in an accurate fashion. Try using tape or a few extra set of hands. Another option is to take the models in OnShape and design a 3D printer hole locator helper. Ream tuner tapered holes until tuners appear ready to be pushed into place (figure out this criteria better with practice). Push tuners into place by hand. Cut out the touchscreen tongue hole with a machine. Consult with your makerspace on how to do this properly.

Prepare a surface with plastic sheeting. Mix the stain with the diluting agent in a throwaway bucket. Paint on the Martone Frames and cover plates with the stain. Clean brushes with the diluting agent and let Martone frames dry.

Touchscreen Prepare the following materials (if in a roll lay out flat ahead of time): ● Thin Rubber Sheet ● Thick Rubber Sheet ● Thick Rubber Sheet ● Piezoresistive Sheet ● Polycarbonate Sheet 9

Figure 4: Martone Touch Screen Layers

Figure 5: Tongue Hole

In Onshape, in the Final Martone Design Folder, go to the flat version file of the layer to be laser cut in the Martone Upper Frame file. Right click the tab and create a drawing. Size the drawing to fit the page and remove any tables and headings. Right click the tab and export to pdf. Load the pdf into the laser cutting software designated to the printer to be used. Select all and configure the settings depending upon the material to be cut or rastered. Values can easily be found online. Test settings on scrap material before committing. Set the material on the laser bed. Check the laser distance to material and change if necessary. Run the laser cutter. For the piezoresistive sheet and polycarbonate sheet, raster the image onto masking tape stuck onto the 10 material ahead of time. Then cut the material with a paper cutter and drill as required. For rubber, clean the rubber with soap and water after cutting. Remove all LED holes if they do not fall out on their own.

Figure 6: LED Cabling Diagram

Place Thin Rubber Layerin the touchscreen bed on the upper Martone Frame. Place Thick Rubber Bottom Layer in the touchscreen bed. Place LED PCBs in their cutout locations. Wire Cables through the upper frame tongue hole. Place Thick Rubber Top Layer above LED PCBs. Place an electrode layer and wire tongue through the tongue hole. Place Piezoresistive Layer. Place Polycarbonate Layer. Place cover plates and screw the eight screw posts into place on the upper frame.

Speaker Grills: Press flat as best as possible on the grill. Create a file for waterjet in the same manner the laser cut files were generated. For shaping the grill to the elliptical shape of the frame, two options exist. Either design and print 3D printed press parts per the shape in the OnShape model, or attempt to bend the grill against an elliptical surface (spare frame or 3D print). Place two cut circles in between the 3d printed press parts. Screw down the four corners with a hand drill. Let sit for a day. Repeat for the other speaker grill.

Attachment Assembly For general guidance on part locations and orientation consult OnShape Martone Full Assembly MSD2 file in Final Martone Design Folder.

Bring together all inserts and two frames. Place inserts in their designated locations and ensure everything fits and lines up properly, mark each location with a light pencil mark. Prepare a tub of superglue/wood glue/2part epoxy and brush onto each insert before placing on the frame. Press firmly into place and allow glue to dry for a minute before gluing the next insert. Glue speaker grills into place as well. Before gluing in magnet and dowel insert, verify dowels line up with holes as best as possible.

Legs 1. Machine Tripod Leg Holder and Leg Tube to specifications in drawing prints 2. Screw in Tripod Leg Holder to Speaker/Leg Insert with 91792A540 screws 3. Screw in screw posts for leg tube and Tripod Leg Holder with 93121A335 screwpost

Figure 7: PCB Cabling Diagram PCB 1. Place rigid pcb into the cutout, making sure all the mounting holes line up. 2. Secure mounting screws into the mounting holes. 3. Screw the proximity sensor cable into the sensor-mounting bracket. 4. Screw the LED cable into the LED-mounting bracket. 5. Screw each of the USB cables into their respective brackets. 12

6. Screw the speakers and audio output jacks into their respective mounting brackets. 7. Solder the speaker wires onto the speakers. 8. Connect the switch cable into the switch jack. 9. Connect the ribbon cable of the electrode pcb into the clamping bracket. 10. Place the battery in the designated mounting spot and connect to the rigid PCB.

Figure 8: Speaker Cabling Diagram

Speakers Placement: 1. Place speakers in 3d printed inserts 2. Run positive and negative outputs through the holes of the inserts to speakers 3. Attach positive lead to positive terminal of speaker 4. Attach negative lead to negative terminal of speaker 5. Solder both terminals 6. Repeat step 1 to 5 for second speakers

Battery Placement: 1. Place the battery in the 3d printed inserts 2. Connect positive and negative leads to V bat 3. Tighten screws to V bat to fasten the battery’s lead