[Elecraft] Wrong PIM nuts in KPA500 kit

2018-02-06 Thread j...@kk9a.com 
A 4-40 Pem nut typically requires a Ø.166 hole and a 6-32 requires a Ø.188
hole. So if a 4-40 nut was installed in a Ø.188 hole it will easily fall
out. You should not re-tap the threads or use a smaller screw. You can
install PEM fasteners with a hammer and anvil but it is best to use a
machine designed for this.

John KK9A

Michael Blake  wrote:

I received a call back from Elecraft Technical Support yesterday.  It was
quite difficult to come together on exactly which screws and embedded PEM
nuts I was talking about in the bottom cover.  Once we were in agreement
on the screw positions I was talking about the technician looked at a
bottom cover but was unable to determine the exact thread sizes as he was
unwilling to remove the green protective tape which covered the holes.  He
was not really equipped to handle this mechanical sheet metal problem but
was going to refer it to another group which could more easily address the
problem.  I initially got the impression that he thought that I was
incorrect about the threaded nut (PEM nuts)  error but I think we got past
that.

For clarification, if you have a new kit and would check, these are the
steps where the problems arise:

These are the steps in the Kit Assembly Instructions

Page 15, figure 14 show six (6) 1/4" 6-32 BLACK FLAT HEAD SCREWS. The
right hand two (2) 6-32 screw locations were equipped with 4-40 threaded
nut inserts (PEM nuts) rather than the correct 6-32 threaded inserts (PEM
nuts).  The two (2) 4-40 BLACK FLAT HEAD SCREW shown in this figure were
correctly equipped with 4-40 threaded inserts (PEM nuts).

The same problem exists on the right hand side cover.

Page 24, figure 32 instructs you to install four (4) 6-32 BLACK FLAT HEAD
SCREWS.  In this case the two rear 6-32 screw locations were equipped with
the correct 6-32 threaded inserts (PEM  nuts) but the front two locations
were equipped with 4-40 threaded inserts (PEM nuts).

At this point I am waiting to see what they find when they check their
current supply of bottom covers and what their recommendation will be to
correct the problem.

I do have a photo but I do not believe I can attach it to the reflector.

Michael Blake
k9jri at mac.com

On Jan 27, 2018, at 11:06 AM, Michael Blake  wrote:

I am waiting on a response from Elecraft TS on this one but I thought I
would ask if anyone else has encountered this problem on the KPA500 kit.

On the bottom edge of both the right and left side panels there are places
for three 6-32 flat head screws. The countersunk holes are obviously
larger than those for the other 4-40 flat head screws.

In my kit one of the three PIM nuts, for each side, was the correct 6-32
thread PIM nut and the remaining two had 4-40 PIM nuts installed in the
bottom cover. When I had temporarily installed the left hand side panel in
the middle of construction I failed to notice this and just installed
screws that fit (one 6-32 and two 4-40) but during final assembly it
became obvious that the 6-32 screws would not fit in 4 of the 6 positions.

Thinking that they just had paint in them I tried tp run a 6-32 tap
through one and it naturally seized up and twisted the PIM nut out. Not
being the brightest bulb in the shop I tried that a second time and
twisted out the second PIM nut.

Fortunately these were both on the right hand side where there was room to
slip two 6-32 hex nuts in place and I just used two 4-40 flat head screws
on the left side.

Hopefully Elecraft will be able to send me the correct PIM nuts to replace
the four incorrect ones. That was my request in the email to Doug at tech
support.

I certainly would not want to replace the bottom coverl as that would
require a complete disassembly of the amplifier.

Has anyone else encountered this?

Michael Blake
k9jri at mac.com

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[Elecraft] Wrong PIM nuts in KPA500 kit

2018-02-06 Thread john 
A 4-40 PEM nut typically requires a .166 diameter hole and a 6-32 requires a
.188 hole. So if a 4-40 nut was installed in a.188 hole it will not grip the
material properly and it will eventually fall out. You should not re-tap the
threads to correct the problem or use a smaller screw. You can install PEM
fasteners with a hammer and anvil however there are insertion machines
designed for this task.

John KK9A

Michael Blake  wrote:

I received a call back from Elecraft Technical Support yesterday.  It was
quite difficult to come together on exactly which screws and embedded PEM
nuts I was talking about in the bottom cover.  Once we were in agreement
on the screw positions I was talking about the technician looked at a
bottom cover but was unable to determine the exact thread sizes as he was
unwilling to remove the green protective tape which covered the holes.  He
was not really equipped to handle this mechanical sheet metal problem but
was going to refer it to another group which could more easily address the
problem.  I initially got the impression that he thought that I was
incorrect about the threaded nut (PEM nuts)  error but I think we got past
that.

For clarification, if you have a new kit and would check, these are the
steps where the problems arise:

These are the steps in the Kit Assembly Instructions

Page 15, figure 14 show six (6) 1/4" 6-32 BLACK FLAT HEAD SCREWS. The
right hand two (2) 6-32 screw locations were equipped with 4-40 threaded
nut inserts (PEM nuts) rather than the correct 6-32 threaded inserts (PEM
nuts).  The two (2) 4-40 BLACK FLAT HEAD SCREW shown in this figure were
correctly equipped with 4-40 threaded inserts (PEM nuts).

The same problem exists on the right hand side cover.

Page 24, figure 32 instructs you to install four (4) 6-32 BLACK FLAT HEAD
SCREWS.  In this case the two rear 6-32 screw locations were equipped with
the correct 6-32 threaded inserts (PEM  nuts) but the front two locations
were equipped with 4-40 threaded inserts (PEM nuts).

At this point I am waiting to see what they find when they check their
current supply of bottom covers and what their recommendation will be to
correct the problem.

I do have a photo but I do not believe I can attach it to the reflector.

Michael Blake
k9jri at mac.com

On Jan 27, 2018, at 11:06 AM, Michael Blake  wrote:

I am waiting on a response from Elecraft TS on this one but I thought I
would ask if anyone else has encountered this problem on the KPA500 kit.

On the bottom edge of both the right and left side panels there are places
for three 6-32 flat head screws. The countersunk holes are obviously
larger than those for the other 4-40 flat head screws.

In my kit one of the three PIM nuts, for each side, was the correct 6-32
thread PIM nut and the remaining two had 4-40 PIM nuts installed in the
bottom cover. When I had temporarily installed the left hand side panel in
the middle of construction I failed to notice this and just installed
screws that fit (one 6-32 and two 4-40) but during final assembly it
became obvious that the 6-32 screws would not fit in 4 of the 6 positions.

Thinking that they just had paint in them I tried tp run a 6-32 tap
through one and it naturally seized up and twisted the PIM nut out. Not
being the brightest bulb in the shop I tried that a second time and
twisted out the second PIM nut.

Fortunately these were both on the right hand side where there was room to
slip two 6-32 hex nuts in place and I just used two 4-40 flat head screws
on the left side.

Hopefully Elecraft will be able to send me the correct PIM nuts to replace
the four incorrect ones. That was my request in the email to Doug at tech
support.

I certainly would not want to replace the bottom coverl as that would
require a complete disassembly of the amplifier.

Has anyone else encountered this?

Michael Blake
k9jri at mac.com

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Re: [Elecraft] Wrong PIM nuts in KPA500 kit

2018-02-06 Thread Michael Blake 
I just received a response from Elecraft. They are sending me a new bottom 
cover and a noise kit for some transformer noise that I had not previously 
mentioned here. While this will involve me tearing down the amplifier and then 
rebuilding it the outcome will be a properly constructed amplifier. 

In all fairness they did offer to repair it at Elecraft but I declined because 
of shipping and insurance cost and not having appropriate packing since it was 
a kit. 

It was a good response I think.  Thank you Elecraft. 

Michael Blake
k9...@mac.com


> On Jan 27, 2018, at 11:04, Michael Blake  wrote:
> 
> I am waiting on a response from Elecraft TS on this one but I thought I would 
> ask if anyone else has encountered this problem on the KPA500 kit.
> 
> On the bottom edge of both the right and left side panels there are places 
> for three 6-32 flat head screws.  The countersunk holes are obviously larger 
> than those for the other 4-40 flat head screws.
> 
> In my kit one of the three PIM nuts, for each side, was the correct 6-32 
> thread PIM nut and the remaining two had 4-40 PIM nuts installed in the 
> bottom cover.  When I had temporarily installed the left hand side panel in 
> the middle of construction I failed to notice this and just installed screws 
> that fit (one 6-32 and two 4-40) but during final assembly it became obvious 
> that the 6-32 screws would not fit in 4 of the 6 positions.
> 
> Thinking that they just had paint in them I tried tp run a 6-32 tap through 
> one and it naturally seized up and twisted the PIM nut out.  Not being the 
> brightest bulb in the shop I tried that a second time and twisted out the 
> second PIM nut.
> 
> Fortunately these were both on the right hand side where there was room to 
> slip two 6-32 hex nuts in place and I just used two 4-40 flat head screws on 
> the left side.
> 
> Hopefully Elecraft will be able to send me the correct PIM nuts to replace 
> the four incorrect ones.  That was my request in the email to Doug at tech 
> support.
> 
> I certainly would not want to replace the bottom coverl as that would require 
> a complete disassembly of the amplifier.
> 
> Has anyone else encountered this?
> 
> Michael Blake
> k9...@mac.com
> 
> __
> Elecraft mailing list
> Home: http://mailman.qth.net/mailman/listinfo/elecraft
> Help: http://mailman.qth.net/mmfaq.htm
> Post: mailto:Elecraft@mailman.qth.net
> 
> This list hosted by: http://www.qsl.net
> Please help support this email list: http://www.qsl.net/donate.html
> Message delivered to k9...@mac.com
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[Elecraft] Wrong PIM nuts in KPA500 kit

2018-01-31 Thread j...@kk9a.com 
You can install PEM nuts with a hammer and anvil but it's best to do it
with a PEM insertion machine or a fixture in a press. 4-40 nuts typically
require a .166 diameter hole and 6-32 require a .188 hole.

John KK9A


Michael Blake K9JRI wrote:

I am waiting on a response from Elecraft TS on this one but I thought I
would ask if anyone else has encountered this problem on the KPA500 kit.

On the bottom edge of both the right and left side panels there are places
for three 6-32 flat head screws.  The countersunk holes are obviously
larger than those for the other 4-40 flat head screws.

In my kit one of the three PIM nuts, for each side, was the correct 6-32
thread PIM nut and the remaining two had 4-40 PIM nuts installed in the
bottom cover.  When I had temporarily installed the left hand side panel
in the middle of construction I failed to notice this and just installed
screws that fit (one 6-32 and two 4-40) but during final assembly it
became obvious that the 6-32 screws would not fit in 4 of the 6 positions.

Thinking that they just had paint in them I tried tp run a 6-32 tap
through one and it naturally seized up and twisted the PIM nut out.  Not
being the brightest bulb in the shop I tried that a second time and
twisted out the second PIM nut.

Fortunately these were both on the right hand side where there was room to
slip two 6-32 hex nuts in place and I just used two 4-40 flat head screws
on the left side.

Hopefully Elecraft will be able to send me the correct PIM nuts to replace
the four incorrect ones.  That was my request in the email to Doug at tech
support.

I certainly would not want to replace the bottom coverl as that would
require a complete disassembly of the amplifier.

Has anyone else encountered this?

Michael Blake

__
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Re: [Elecraft] Wrong PIM nuts in KPA500 kit

2018-01-30 Thread Michael Blake 

I received a call back from Elecraft Technical Support yesterday.  It was quite 
difficult to come together on exactly which screws and embedded PEM nuts I was 
talking about in the bottom cover.  Once we were in agreement on the screw 
positions I was talking about the technician looked at a bottom cover but was 
unable to determine the exact thread sizes as he was unwilling to remove the 
green protective tape which covered the holes.  He was not really equipped to 
handle this mechanical sheet metal problem but was going to refer it to another 
group which could more easily address the problem.  I initially got the 
impression that he thought that I was incorrect about the threaded nut (PEM 
nuts)  error but I think we got past that.

For clarification, if you have a new kit and would check, these are the steps 
where the problems arise:

These are the steps in the Kit Assembly Instructions

Page 15, figure 14 show six (6) 1/4" 6-32 BLACK FLAT HEAD SCREWS. The right 
hand two (2) 6-32 screw locations were equipped with 4-40 threaded nut inserts (PEM 
nuts) rather than the correct 6-32 threaded inserts (PEM nuts).  The two (2) 4-40 
BLACK FLAT HEAD SCREW shown in this figure were correctly equipped with 4-40 
threaded inserts (PEM nuts).

The same problem exists on the right hand side cover.

Page 24, figure 32 instructs you to install four (4) 6-32 BLACK FLAT HEAD 
SCREWS.  In this case the two rear 6-32 screw locations were equipped with the 
correct 6-32 threaded inserts (PEM  nuts) but the front two locations were 
equipped with 4-40 threaded inserts (PEM nuts).

At this point I am waiting to see what they find when they check their current 
supply of bottom covers and what their recommendation will be to correct the 
problem.

I do have a photo but I do not believe I can attach it to the reflector.

Michael Blake
k9...@mac.com

On Jan 27, 2018, at 11:06 AM, Michael Blake  wrote:

I am waiting on a response from Elecraft TS on this one but I thought I would 
ask if anyone else has encountered this problem on the KPA500 kit.

On the bottom edge of both the right and left side panels there are places for 
three 6-32 flat head screws. The countersunk holes are obviously larger than 
those for the other 4-40 flat head screws.

In my kit one of the three PIM nuts, for each side, was the correct 6-32 thread 
PIM nut and the remaining two had 4-40 PIM nuts installed in the bottom cover. 
When I had temporarily installed the left hand side panel in the middle of 
construction I failed to notice this and just installed screws that fit (one 
6-32 and two 4-40) but during final assembly it became obvious that the 6-32 
screws would not fit in 4 of the 6 positions.

Thinking that they just had paint in them I tried tp run a 6-32 tap through one 
and it naturally seized up and twisted the PIM nut out. Not being the brightest 
bulb in the shop I tried that a second time and twisted out the second PIM nut.

Fortunately these were both on the right hand side where there was room to slip 
two 6-32 hex nuts in place and I just used two 4-40 flat head screws on the 
left side.

Hopefully Elecraft will be able to send me the correct PIM nuts to replace the 
four incorrect ones. That was my request in the email to Doug at tech support.

I certainly would not want to replace the bottom coverl as that would require a 
complete disassembly of the amplifier.

Has anyone else encountered this?

Michael Blake
k9...@mac.com

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[Elecraft] Wrong PIM nuts in KPA500 kit

2018-01-27 Thread Michael Blake 
I am waiting on a response from Elecraft TS on this one but I thought I would 
ask if anyone else has encountered this problem on the KPA500 kit.

On the bottom edge of both the right and left side panels there are places for 
three 6-32 flat head screws.  The countersunk holes are obviously larger than 
those for the other 4-40 flat head screws.

In my kit one of the three PIM nuts, for each side, was the correct 6-32 thread 
PIM nut and the remaining two had 4-40 PIM nuts installed in the bottom cover.  
When I had temporarily installed the left hand side panel in the middle of 
construction I failed to notice this and just installed screws that fit (one 
6-32 and two 4-40) but during final assembly it became obvious that the 6-32 
screws would not fit in 4 of the 6 positions.

Thinking that they just had paint in them I tried tp run a 6-32 tap through one 
and it naturally seized up and twisted the PIM nut out.  Not being the 
brightest bulb in the shop I tried that a second time and twisted out the 
second PIM nut.

Fortunately these were both on the right hand side where there was room to slip 
two 6-32 hex nuts in place and I just used two 4-40 flat head screws on the 
left side.

Hopefully Elecraft will be able to send me the correct PIM nuts to replace the 
four incorrect ones.  That was my request in the email to Doug at tech support.

I certainly would not want to replace the bottom coverl as that would require a 
complete disassembly of the amplifier.

Has anyone else encountered this?

Michael Blake
k9...@mac.com

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