Joining 2 Keyboards.

Please not this method is only for this type of keyboard but does give some idea of how to perform the same operations on other keyboard types.




Tools Required :-

Rule

Scriber

Sliding Square (small)

Square

Large Hacksaw

Small Hacksaw

Screwdrivers

Drill and Drill Bits

Metal File

Centre Punch

Vice

Self Tapping Screws

Tools Optional :-

9” Grinder with Metal Cutting Disc

5” Grinder with Metal Grinding Disc

Grinder Stand for 9” Grinder

Electric Welder

Vernier Calipers

Here is where we start.

 
 
 
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The first job is to remove all but the basic keyboard parts to make it easier to work on.

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Then remove all the keys to leave the basic frame.

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Now it is time to remove the excess material to leave a small sub frame for the extra 17 keys.Then after cutting the frame down

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 I used the spare end rail and re-screwed it and the contact carrier which had also been cut down to make a smaller frame.

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Repeat the operation on the other frame to remove any excess length to make it possible to join up the 2 keyboards. 
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At this point when cutting the frames you will need to cut halfway between the key fulcrum slots to enable the correct spacing when re-joining the frames, this is where the vernier calliper comes in useful.

This is where the 9” grinder in a bench stand really becomes useful, with careful adjustment of the fence you can cut the frames nice and straight to get a good clean joint.

It is also good for cutting of the unwanted frame members and cutting the the pcb carrier.

Once you have the 2 frames they can be checked for a good fit, when you are satisfied with the fit drill holes in the end strips and bolt the 2 frames together.

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Then it is just a case of cleaning and replacing the keys.

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You will find that 2 of the keys will impinge on the frame joint but the excess part of the underside of the key can be cut off

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Now we turn our attention to the key contacts, on this keyboard they are all mounted on a pcb so it is relatively easy to hacksaw off the unwanted length. 
With a bit of careful paring the pcb’s can be remounted in the same screw holes.

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My next job is to pull the return wires out of their supports and give them a good clean along with the spring contacts, then reassemble.

All that is then left to do is remove the old unwanted components and join up the 3 spring contacts for each key. 
This step is not really necessary but will give me 3 chances of a key making a good contact when pressed.

I hope that gives you some idea of how to join keyboards, some are relatively straight forward as this one is but some are a real nightmare as I hope to show you in the next article.

Please let me know if this has been useful or if you have any questions.

Just email me at martin@end-task.com