Tag: manufacture

  • The Lost Art of Understanding Our Radios

    The Lost Art of Understanding Our Radios

    The Bad Place: Before the Radio Theory was known by Operators

    At the dawn of the 20th century, radio was mysterious, fragile, and poorly understood. Communication over distance relied on cables, messengers, and guesswork. Early wireless systems were unstable, interference-prone, and often unreliable.

    Radio existed, but understanding our radio would take a while.

    This was the bad place: a world that knew radio was powerful, but didn’t yet understand how to control it, refine it, or trust it.


    Pride: Mastery Through Hands-On Radio

    understanding our radio

    Following World War I—and through the rise of the British Empire’s global communications network—radio entered a golden age of understanding.

    By the early 20th century, radio was no longer confined to governments and industry. It became a technology that individuals could build, modify, repair, and improve—often with parts and knowledge they acquired themselves.

    In the United States especially, amateurs were:

    • Winding coils by hand
    • Building transmitters from discrete components
    • Repairing receivers at home or in the field
    • Understanding circuits because they had to

    Radios were not sealed products; they were instruments. Accessories, antennas, tuners, and power supplies were designed, shared, and iterated on locally.

    This was a time of justified pride:

    • Pride in skill
    • Pride in understanding
    • Pride in independence

    Amateur radio wasn’t about owning technology. It was about knowing it.


    The Warning: Convenience Replaces Curiosity

    As decades passed, radios improved rapidly. Reliability increased. Miniaturization accelerated. Eventually, radios became consumer products.

    The warning signs were subtle:

    • Schematics became harder to obtain
    • Repairs shifted from component-level to board replacement
    • Surface-mount parts replaced accessible through-hole designs
    • Firmware replaced circuits

    The hobby didn’t collapse—but something quietly changed.

    Understanding became optional.

    As long as the radio worked, curiosity was no longer required.


    The Fall: When Repair Leaves the Community

    understanding our radio

    The fall didn’t happen all at once. It happened when radios stopped being repairable by their owners.

    Today, a large percentage of amateur radio operators can no longer work on their own equipment—not because they lack intelligence, but because the ecosystem no longer supports it.

    I live in a region dense with technical talent and higher education—multiple colleges, engineering programs, and skilled professionals. Yet when my 1994 Yaesu HF transceiver failed, the prevailing advice wasn’t local troubleshooting or schematic analysis.

    It was:
    “Send it to a repair shop in Florida.”

    A decades-old amateur radio.
    Shipped across the country.
    Because no one nearby could fix it.

    That moment marks the fall.


    The Worse Place: Where We Are Now

    This is the worse place—and it’s where we are today.

    Modern amateur radio is dominated by extraordinary equipment designed by companies like Yaesu, Icom, and Kenwood—companies that hold decades of accumulated HF intellectual property. Understanding our radio or anyone else’s for that matter is pipe-dream.

    The radios are brilliant.
    The performance is stunning.
    The knowledge is sealed away.

    Much of the global East now creates and maintains the understanding, while most of the U.S. amateur community just consumes the results.

    We buy the radios.
    We compare features.
    We are satisfied—as long as they work.

    But when they don’t, the answer is no longer “Let’s fix it.”
    The answer is “Where do we get it fixed?”

    Like every other consumer electronic device, we buy another one. This doesn’t feel right.

    That is not where amateur radio began—and it is not where it thrives.


    Why This Matters to Clubs and the Future

    At Johnston Amateur Radio Society, like many clubs across the country, we’re focused on membership growth and engaging new operators.

    Younger, technically curious people want more than polished tools. They want to be captured by the technology.

    • To understand how our radios work
    • To trace signals
    • To be able to repair what breaks
    • To customize and build what doesn’t exist

    Remember the Erector Set? Radios don’t engage this kind of behavior today. What they do is put a seal on the enclosure and tell you your warranty will be voided if you break it.

    If amateur radio becomes only an appliance hobby, it loses the very spark that once made it revolutionary.


    My Goal: Reversing the Arc

    With my HF SSB radio project, I’m not trying to recreate the entire body of global RF knowledge. That would be unrealistic.

    What I am trying to do is interrupt the fall:

    • Bring schematics back into the conversation
    • Treat RF as something understandable, not mystical
    • Talk about models, stability, noise, and tradeoffs
    • Encourage building, not just buying

    If we can reclaim even part of this understanding locally, repairability—and pride—returns with it.


    Why This Article Uses the “Pride and Fall” Story Model

    This article follows the Pride and Fall narrative structure described in Storyteller Tactics by Steve Rawling (Pipdecks):

    Bad Place – Radio existed but wasn’t understood

    Pride – Mastery through hands-on experimentation (1918–1939)

    Warning – Convenience quietly replaces understanding

    Fall – Operators lose the ability to repair their own tools

    Worse Place – We rely on distant experts and sealed knowledge

    This structure matters because it mirrors reality:
    Progress without participation doesn’t lead upward—it leads outward, away from us.

    Understanding our radios is not nostalgia.
    It’s the foundation of resilience.

    And amateur radio deserves to stand on it again.


    My About page provides the background of my project, the Freedom7 HF Transceiver.

    If this story resonates, comments are welcome. You can also reach me at david [at] kr4bad-dot-communications. no com

    And if you believe understanding our radio matters more than black boxes, you can subscribe to my WordPress https://kr4bad.com/?subscribe=1.

    73 KR4BAD David

  • Review of PCBWay: Quality and Value for My 5 Band-Pass Filter PCBs

    Review of PCBWay: Quality and Value for My 5 Band-Pass Filter PCBs

    My small order for a single PCB, required the manufacture of at least 5 PCBs of the same type. The boards were shipped with DHL direct to my home from PCBWay in China. Quality and value are what arrived in well-packaged box on my front porch.

    Arrival

    The boards arrived exactly as notified. I was impressed with the care taken in packaging—the box was well protected, and the PCBs were sealed in PCBWay’s packaging with desiccant included for moisture control. All five boards were clean, flat, and well protected.

    I inspected the boards for any visible manufacturing defects and found none. The finished PCBs accurately reflected the Gerber and drill files I provided to PCBWay.

    Inspection

    This PCB design had pads I designed to provide a mounting for Harwin RFI enclosure clips. I realized during assembly that the surface tension at solder melt would perfectly align these clips. PCBWay oriented them 90 degrees to how they should have been, again exactly as I specified in the Gerber files. I measured these pad coordinates relative to the edge references and they were perfect! We’ll fix that final version.

    I am constantly aware of the heat being applied to the SMD components. I was closely paying attention to the PCB as items were individually being soldered. I.e. I was looking for any defect in the printed circuit board (PCB) from the high temperature being used with the liquid solder (285 C). Everything held together for the entire assembly.

    Because this design uses surface-mount components, I paid close attention to how the board handled heat during soldering. Each component was soldered individually at approximately 285 °C, and I carefully watched for any signs of delamination, pad lifting, or trace damage. The PCB remained mechanically and electrically sound throughout the entire assembly process.

    The product was solid.

    quality

    I did not individually probe every trace. For a large or densely populated board, I likely would have. This design is intentionally simple—three inductors and five capacitors forming an RF filter—so functional testing after assembly was the most practical and meaningful validation.

    To complete the RF shielding, I fabricated a cover using 0.2 mm sheet aluminum. This enclosure, open on the bottom, mates with the Harwin clips and fully shields the passive RF components.

    Testing

    Final testing was performed using a NanoVNA. The results exceeded my expectations, with an insertion loss of just –0.84 dB. Yes—very pleased with that result.

    Final Review

    Overall, I was extremely satisfied with the entire PCB manufacturing experience, from the initial order process through final testing. Every stage—shipping updates, production notifications, delivery timing, arrival condition, physical inspection, verification against design files, hands-on assembly, and final RF performance testing—met or exceeded my expectations for a professionally manufactured printed circuit board.

    I am not a salesperson or affiliate. I approach this strictly as a designer and engineer who cares deeply about accuracy, repeatability, and real-world performance. From that perspective, PCBWay delivered exactly what was promised. The finished boards matched my Gerber and drill files precisely, arrived well-packaged and protected, and withstood both mechanical handling and high-temperature soldering without issue.

    What stood out most was the overall workmanship-to-price ratio. For a technically demanding RF project—specifically a 20-meter band-pass filter PCB—the manufacturing quality, dimensional accuracy, and electrical reliability were excellent, especially given the cost. The boards performed as designed once assembled, and the measured RF results confirmed that the PCB fabrication did not introduce unexpected losses or defects.

    Based on this experience, I can confidently recommend PCBWay to other engineers, designers, and amateur radio builders who are looking for reliable PCB manufacturing services at a competitive price. The combination of order creation, build workmanship, general communication, shipping notifications, and product value makes PCBWay a strong choice for both prototype and small-batch production work.

    I’ll also refer this posting mentioning PCBWay ‘s suite of other services.


    My About page provides the background of my project, the Freedom7 HF Transceiver.

    If this story resonates, comments are welcome. You can also reach me at david [at] kr4bad-dot-communications. no com

    And if you believe understanding matters more than black boxes, you can subscribe to my WordPress https://kr4bad.com/?subscribe=1.

    73 KR4BAD David