deskthority

Hello,

For some time now I have had an idea stuck in my head: to build my own keyboard.

Luckily, I came across the awesome build the Photekq did a year ago, the TEK-80: https://geekhack.org/index.php?topic=54422.0
Photekq was also kind enough to provide, in the TEK-80 topic, the CAD files he has created and used so I had a base to start from.
I have also asked for his permission to use his design and files.

DISCLAIMER: I have never even opened a CAD software suite before 3PM on Saturday 28'th of March (last week) when I installed SolidWorks.

I powered through learning SolidWorks, trial and error and modifying Photekq TEK-80 design (all at the same time) until 6 AM on Sunday (29th of March), when I finally realized that I need some sleep.

I kept working during the week after work and made the design for a numpad, several plates, top cases, and a new bottom case.
My plan is so make this TKL work with a GON NERD Tkl V2 pcb: http://www.gonskeyboardworks.com/pcbs-a ... l-smt.html
I may modify it to work with a Winkeyless B.87pcb which has the usb connector next to the ESC key: http://winkeyless.kr/?product=b-87r-pcb
Regarding the numpad PCB, I have no idea what PCB I would use, maybe a GONPAD or a Winkeyless B.pad PCB
Anyway, I'm still open for ideas regarding PCB's.

I tried to keep the design as industrial and as simple as possible.
I wanted the keyboards to have a smaller height than the TEK-80 for comfort.
I also wanted to make everything compatible with the TEK-80 (in case someone likes my base but Photekq's top case, plate, they can use it without a problem.
To keep the keyboard and the numpad on the heavy side and simple to manufacture I removed the brass plate/weight cutout and I made the case thicker on the inside (to have the same distance from the PCB, even If the case is at angle)
Sadly I have not found any measuring regarding GON's NerD tkl PCB to really check where I should put the connector hole in the TKL case and I "eye measured" it.
Do any of you have an exact measurement of GONs NerD TkL pcb so I can correct any errors?

Also, I would really appreciate if you would take look at the design and CAD files and tell me where I messed up. As I said at the beginning, this is my very first time using a CAD software

This project was unexpectedly difficult and I almost rage-quit on it 2 or 3 times (mainly because my lack of experience with SolidWorks). But it was also a huge learning experience and allot of fun (and I had the perfect music to help me concentrate - see at the end of the post).

Anyway, enough talk. The "stuff" now:

Here is the link to the CAD files: https://www.dropbox.com/s/xy1sysjpqojak ... KL.7z?dl=0

Insipired by:



All together (my favourite):



I have also been thinking at a layout similar to this one: http://www.keyboard-layout-editor.com/# ... f9ffeda8c1

Made quick top case design for it too:



Finally, here is the album link (with more images): http://imgur.com/a/Kzzwy

And the industrial-glitch-idm music (made by a good friend) that helped to keep me concentrated while working on this project: http://raumklangmusic.bandcamp.com/album/polymath

Ooooooh. Very very interesting. Please load the images inline with tags to make it easier to read!

scottc wrote: ↑Ooooooh. Very very interesting. Please load the images inline with tags to make it easier to read!

Done!

Thanks! By the way, GON shares DWG files with measurements of his PCBs on his site.

Edit; whoops, I meant [img] tags!

scottc wrote: ↑Thanks! By the way, GON shares DWG files with measurements of his PCBs on his site.

Edit; whoops, I meant [img] tags!

Oh, I did not know that. Should have checked deeper on his site.

[img] tags - done

Aaah, much better.

The measurements should be here in the manuals section, if you haven't found them yet: http://www.gonskeyboardworks.com/manual ... -pcbs.html

scottc wrote: ↑Aaah, much better.

The measurements should be here in the manuals section, if you haven't found them yet: http://www.gonskeyboardworks.com/manual ... -pcbs.html

Found them too

I feel pretty dumb now for not looking deeper on his site

Anyway, I'll modify the case a bit later. Now I have to take the bicycle out for a ride

Very interesting Next step make a prototype I buddy of mine found a good CNC here in Romania and made some parts, those guys did a great job and the price was decent.

I'd love one of these, in case that wasn't obvious from my previous frantic typing. I've always wanted a full-aluminium TKL, but I could never justify the price for a real full-metal Korean custom like the 356 or 360c.

DanielT wrote: ↑Very interesting Next step make a prototype I buddy of mine found a good CNC here in Romania and made some parts, those guys did a great job and the price was decent.

Can you give me a PM with some details regarding the CNC shop?

I also have a friend (the one that made the music I linked at the end of the original post) who is very handy with electronics and mechanics and he designed and built a CNC machine for the company he works at (here in Bucharest). I talked with him regarding my design, but I would like to have more options.

I will ask my buddy on monday, the shop is in Timisoara and they have a big industrial CNC whitch is the best option for big works like a keyboard case. They have also materials, very good aluminum aloy.
I will shoot you a PM after I know more details. As for the price they charged around 40EUR for a complicated piece, the prices go lower if you want more.

Very interesting! How are you going to incorporate the separate numpad? Separate microcontroller or will it connect to the main board?

photekq wrote: ↑derzemel, I've just had the chance to have a proper look at this.

The design looks great! I'm going to go over the CAD files in the next few days to see if I can spot any problems.

The only problem I've seen so far is that the space between the F-row and num-row is the same as I had it for the Phantom PCB. The NerD PCB has a smaller gap.

Thank you very much for taking the time to look at them!
Luckily, I also found out that GON and Winkeyless use a smaller gap between the f-row and num-row before I decided to send the design to a CNC shop.
They are kind enough to provide .dxf and .dwg files with the sizing for the pcb (GON) and for the case (winkeyless):
http://www.gonskeyboardworks.com/manual ... -pcbs.html
http://blog.winkeyless.kr/162
Also, Winkeyless has a plate on the korean part of the store: http://winkeyless.kr/store/?product=if-frame
Maybe, If I ask kind enough, he will provide the dxf/dwg file for the plate, or at least some sizing.
I now have to modify the case and plate design to fit the smaller size PCBs, either by shrinking the cases, or by making the sides thicker (I am still hoping to keep the designs interchangeable). But I'll do it sometime next week.
I think that It will look something like the LZ FE case:



Or, maybe I'll be lucky and find a phantom-sized PCB that supports backlight and easily programmable