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BuildInstructions_V1.md

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V1 Build Instructions

BOM

Component Count
Pi Pico 1
Pi Zero W or Pi Zero 2 W 1
Pi Zero 2x20 Header Pins 1
SD Card 1
JMD0.96C OLED Display 1
4 Position DIP Switch 1
0.1" 3 Pin Header + Jumper / 0.1" Pitch SPDT Slide Switch 1
Hotswap Socket 66
Keyboard Switch (Hippo Linear) 66
Keycaps (Redragon Crystal Keycap) 66
EC11 Rotary Encoder 1
Encoder Knob (Glorious) 1
1N4148 Diode 84
M2.6 x 10mm Self Tapping Screws 8
M2.6 x 16mm Self Tapping Screws 7
3mm Acrylic Sheet 2
1.5mm Acrylic Sheet 1
3D Printed Rivet + Spacers 15
JST-PH 2.0mm 4 Pin Female Connector 2
Stablizer Set 1
330Ω THT Resister 1
10kΩ THT Resister 4
1206 0.01 µF Capacitor 2
(Optional) 3.5 inch TFT Display HAT 1
(Optional) 0.1" 3 Pin 90° Header 1
(Optional) 0.1" 4 Pin 90° Header 1

PCB

Everything is in PCB/MainBoard dir. Designed with Kicad 7.0. Make sure Perfect DOS VGA 437 Font is intalled on Windows, or if you use Arch, install the ttf-perfectdos package. PCB/MainBoard/Gerber dir contains the Gerber files for three fab houses: JLCPCB, PCBWay, and OSHPark. For JLCPCB and PCBWay, make sure to select the Castellated Holes option (this will increase the price, but it's better to be safe on the quality side).

Case

The case comprises three acrylic plates and various 3D printed rivets. The original Fusion 360 archive is Frame/MainBoard/CyberKeep 2040 V2 v34.f3d. The spacer heights are parameterized.

Plates Image

The case is held together with 3D printed rivets and spacers.

Step 1: Assemble the rivets and bottom spacers

Place the rivets through the holes on the bottom place. Then fit the spacer rings. Step 1

Step 2: Place the top spacers

Place the PCB on top of the bottom spacers. Then place the top spacers as shown. Step 2

Step 3: Secure the top plates with screws

Place the top bar acrylic plate and the switch plate on top of the top spacers. Then secure the whole assembly with screws. Use M2.6x16mm screws for the top plate, and M2.6x10mm screws for the switch plate. Step 3

Soldering

Pi Zero

Soldering of Pi Zero is the trickiest. You need to solder the pins simultaneously to the keyboard PCB and the Pi Zero, via the castellated hole on the PCB.

Zero_Bottom

This is viewed from the bottom, at the castellated hole. The green PCB is Pi Zero. Solder joint should form between the copper on the keyboard PCB, the plates on Pi Zero PCB and the pin. To make things easier, it's recommended to tape down the Pi Zero and headers:

Zero_Top

It's also recommended to solder all the pins for structural strength.

Diodes

Align the dark side of the diode with the square pad.

Diodes

JST Connector

Install the JST connectors on the back of the PCB. You can either solder on the back side or on the front. If on the front, tape down the connectors first.

JST

JMD0.96C OLED Display (Marked as J4 on the front of the PCB)

If J3 is installed on the back of the PCB, place a tape on the back of the display to avoid shorting.

Software

Keyboard firmware: https://github.com/zli117/PicoMK/tree/main/configs/cyberkeeb_2040. Follow PicoMK's instruction to build the firmware and upload it to Pico microcontroller.

Linux driver for accepting key strokes from SPI: (You'll need an external screen and an external keyboard for this setup)

  1. Install kernel headers: sudo apt install raspberrypi-kernel-headers
  2. Checkout PicoMK: git clone https://github.com/zli117/PicoMK.git
  3. Build the driver and device tree overlay: 
    cd PicoMK/linux
make -j
make device_tree
  4. Install the driver: 
    sudo -E make install
sudo depmod -a
  5. Copy over the device tree overlay: sudo cp spi1-picomk.dtbo /boot/overlays
  6. Add this line to the config.txt. Make sure SPI1 is not enabled. 
    dtoverlay=spi1-picomk
  7. Add this line to the /etc/modules file: 
    spi_picomk

If you're using the 3.5 inch TFT screen, you can install the driver from https://github.com/juj/fbcp-ili9341.