Mod THE PILEDRIVER User manual

1Copyright © 2012 by modkitsdiy.com
Use these instructions to learn:
How to build an effects pedal for clean boost.
The PileDriver is a clean boost that will provide up to 38 dB of voltage gain to your guitar signal. Use it to
push your preamp into overdrive or as a line driver if you are experiencing signal degradation from your
effects chain.
THE PILEDRIVER (K-920)
Unplug when not in use
to save battery life.
Warning: This circuit was designed for use with a 9 VDC power supply only.
Signal Input
(From Guitar)
Signal Output
(To Amplifier)

TABLE OF CONTENTS
TOOL LIST …………………………………………………………………………...2
PARTS LIST DRAWINGS………………………………………………………….3, 4
SOLDERING TIPS …………………………………………………………………...5
STEP BY STEP ASSEMBLY INSTRUCTIONS …………………………………...6
Section 1 – Mount ¼” Jacks and Terminal Strip Components ……………...6
Section 2 – Mount the Potentiometer and Footswitch ………………………...7
Section 3 – Wiring the PileDriver ………..…………………………………...8
Section 4 – Finishing UP ….….…………………………………………...9
ASSEMBLY DRAWINGS (4 Drawings) …………………………………10, 11
These are the last 2 pages. They should be separated and used as a reference to help
assemble the kit correctly.
2
Visit www.modkitsdiy.com if you have any problems when first turning on your pedal for
troubleshooting help. Remember to use caution when applying power to the pedal to avoid electric
shock.
TOOL LIST
Wire Strippers
Needle Nose Pliers
Cutting Pliers
Desoldering Pump
Solder (60/40 rosin core)
Soldering Station
Phillips Head Screwdrivers
Slotted tip screwdrivers (3 mm tip)
Channellock Pliers (or similar type)
Ruler
Hobby Vise (or other means to secure box while working)

Enclosure
P-H1590BBCE-R (1)
Chicken Head Knob
P-K300S (1)
Battery Clip
S-H155 (1)
¼” Mono Jack (Output Jack)
W-SC-11-T (1)
¼” Stereo Jack (Input Jack)
W-SC-12B (1)
#6 Screws (3/8" long)
S-HS632-38 (2)
#6 Nuts
S-HHN632 (2)
Stranded Wire (22 AWG) - Red
K-PUL1569 (3 FT)
PARTS LIST 1
3
RING LUG
GROUND LUG
TIP LUG
GROUND LUG
TIP LUG
5kΩ Potentiometer with Linear Taper
R-VA5KL (1)
1
2
3
Terminal Strip with 8 Terminals
P-0802H (1)
P-QBS170 (1)
N-Channel MOSFET (BS170)
BS170
Caution: MOSFETs can easily be damaged by static
electricity. Handle with care.
DPDT Foot Switch
P-H498 (1)

PARTS LIST 2
4
.1µF
400V
0.1µF Capacitor 400V
C-TD1-400 (1)
1N4005 SOLID STATE DIODE
P-Q1N4005 (2)
green
brown
red
gold
5.1K
5.1kΩ Resistor ½ W
R-A5D1K (1)
R-A100K (1)
100kΩ Resistor ½ W
brown
black
yellow
gold
100K
brown
black
green
gold
1M
R-A1M (2)
1MΩ Resistor ½ W
10µF 50V
C-ET10-50 (1)
10µF Polarized Capacitor 50V

SOLDERING TIPS
1. Bend the component lead
and wrap it around the
connection point.
2. Wrap the component lead
so that it can hold itself to the
connection point.
3. Heat up both component
lead and connection point with
the soldering iron.
4. Apply solder to both
component lead and
connection point.
2. Apply fresh solder to mix in
with old solder joint
1. Heat up old solder joint
with the soldering iron.
3. Use a de-soldering tool to
remove the old solder joint
while it is heated.
De-Soldering Tip
5
It is important to make a good solder joint at each connection point. A cold solder joint is a connection that
may look connected but is actually disconnected or intermittently connected. (A cold solder joint can keep
your project from working.)
Follow these tips to make a good solder joint. Take your time with each connection and make sure that all
components are connected and will remain connected if your project is bumped or shaken.
Bend the component lead or wire ending and wrap it around the connection point.
Make sure it is not too close to a neighboring component which could cause an
unintended connection.
2. Wrap the component lead so that it can hold itself to the connection point.
Touch the soldering iron to both the component lead and the connection point allowing both to
warm up just before applying the solder to them.
Be sure to adequately cover both component lead and connection point with melted solder.
Remove the soldering iron from your work and allow the solder joint to cool. (The
solder joint should be shiny and smooth after solidifying.)
Cut off any excess wire or component leads with cutting pliers.
Clean the soldering iron's tip by wiping it across the wet sponge again after making the
solder joint.

SECTION 1 – Mount ¼” Jacks and Terminal Strip Components
Please refer to DRAWING 1 and DRAWING 2.
Orient box with single centered 5/16" hole on top and ½” hole nearest you.
Mount input jack in 3/8" hole on left side of box with hardware provided.
Washer goes under nut on outside of box. Make sure center solder lug
of input jack is facing up. Correct positioning of jack will make soldering
connections much easier. When positioned correctly, tighten nut.
Mount output jack in 3/8" hole on right side of box with hardware
provided. Washer goes under nut on outside of box. Make sure two
solder lugs are in most upright position before tightening nut.
Mount the terminal strip to the two 9/64" holes as shown in drawing 2.
We will refer to terminal numbers as illustrated below when
connecting components.
input
jack
output
jack
1 2 3 4 5 6 7 8
GROUND LUG
TIP LUG
Output Jack
RING LUG
GROUND LUG
TIP LUG
Input Jack
Terminal #3 will have six components connected to it. Because of this
we will use both the upper and lower portion of the terminal.
lower holes
31 5
Terminals #1 & 3:
“Anode” to terminal #1
“Cathode” to terminal #3
1) Mount the diodes to the lower set of holes, but do not solder.
Terminals #3 & 5:
“Anode” to terminal #3
“Cathode” to terminal #5
cathodeanode
cathode side is
marked with a
silver band
2) Mount one end of the .1µF capacitor to the lower
hole of terminal #3. Now solder the lower set of
holes at terminals #1, 3, and 5.
.1µF
400V
1 5
3
6
Connect and solder all of the following to their respective terminals as listed. (Make sure none of
the component leads are so close together that it could lead to an unintended connection). Be
careful not to overheat the solid state devices (diodes and transistor) when soldering.

Terminals #1 & 3:
mount one of the 1M resistors to 1 & 3.
4) Mount the 1M resistors.
Terminals #3 & 4:
mount the other 1M resistor to 3 & 4.
Terminals #5 & 6:
5) Mount the 5.1K resistor.
Terminals #4 & 6:
6) Mount a 2" piece of wire to connect:
Terminals #6 & 7:
7) Mount the 10µF capacitor.
mount the positive end to terminal 6.
mount the negative end to terminal 7.
Terminals #7 & 8:
8) Mount the 100K resistor.
.1µF
400V
BS170
DS G
1M 1M
5.1K
10µF 50V
100K
1 85
10µF 50V
Positive
End
7
Mount potentiometer using hardware provided. Solder lugs should be pointed to large ½” hole for
footswitch. (You can break off the small mounting tab on the pot by bending it back with pliers).
Mount footswitch in ½” hole. Large nylon washer
goes under mounting nut on outside of box.
Lock washer mounts on inside of box between
the box surface and the other nut. Make sure
that the footswitch solder lugs are oriented left to
right, not up and down as illustrated below.
SECTION 2 – Mount the Potentiometer and Footswitch
Please refer to DRAWING 3.
Terminals #2, 3 & 4:
“Source” to terminal #2
“Gate” to terminal #3
“Drain” to terminal #4
BS170
DSG
3) Mount the BS170 MOSFET.
.1µF
400V
BS170
DS G
The remaining components and wires can be connected to the upper portion of their respective
terminals. Unless otherwise noted, “mount” means to mount the component, solder the component in
place and trim the leads.
This component
is delicate, be
careful not to
burn it or break
off the leads by
bending them
repeatedly.
Cut the wire to length, then strip ¼” of insulation off each end. Twist each end of the stranded wire, and
apply a small amount of solder to each end (i.e. tin the wire ends) before mounting and soldering the
wire ends to their respective terminals.
Caution: MOSFETs can easily be damaged by static electricity. Handle with care.
Incorrect OrientationCorrect Orientation
input
jack
output
jack
1 3
64
2
5

8
SECTION 3 – Wiring the PileDriver
Please refer to DRAWING 4.
Stripping and tinning wire. Throughout these instructions you will be told to strip and tin a length
of wire numerous times. Unless noted otherwise, cut the wire to the length stated in the
instructions. Then strip ¼” of insulation off each end. Twist each end of the stranded wire, and
apply a small amount of solder to each end (tin the wire ends). This will prevent the stranded wire
from fraying and will make the soldering much easier.
1) Strip and tin a 2" piece of wire and connect:
Potentiometer Lug #1.
Terminal Strip #2. 123
1 2 3 4 5 6 7 8
2) Connect the battery clip:
Red wire to Terminal Strip # 5.
Black wire to ring lug of the input jack.
RING LUG
GROUND LUG
TIP LUG
Input Jack
3) Strip and tin a 3" piece of wire and connect:
Footswitch Lug #6.
Terminal Strip #7.
4) Strip and tin a 4" piece of wire and connect:
Footswitch Lug #5.
Tip lug of the output jack.
GROUND LUG
TIP LUG
Output Jack
5) Strip and tin a 1 ½” piece of wire and connect:
Footswitch Lug #1.
Footswitch Lug #4.
6) Strip and tin a 4” piece of wire and connect:
Footswitch Lug #2.
Tip lug of the input jack.
7) Strip and tin a 3” piece of wire (on one end strip off about ½” of insulation) and connect:
Ground lug of output jack.
Potentiometer Lug #2 & 3.
2
3
½” of one of the wire ends is stripped to
allow connection of pot lug #2 and 3.
8) Connect and solder the other end of the .1µF capacitor to footswitch lug #3.
.1µF
400V
3
1 3
64
2
5

SECTION 4 – Finishing Up
Visually inspect all solder connections to make sure everything is connected properly with no cold
solder joints. Make sure none of the component leads are so close together that they could lead to
an unintended short.
Connect a 9 volt battery and place it in the space below the footswitch.
Fasten the cover plate and attach the chicken head knob to the potentiometer shaft.
In order to save battery life, disconnect your guitar cable from the pedal’s input jack when not in use.
9

DRAWING 1
DRAWING 2
10
5/16"
1/2"
9/64" 9/64"
3/8" 3/8"
TOP
INSIDE VIEW OF THE ENCLOSURE
LEFT SIDE
RIGHT SIDE
BOTTOM
INPUT JACK OUTPUT JACK
.1µF
400V
BS170
DS G
1M 1M
5.1K
10µF 50V
100K
1 85

11
.1µF
400V
DRAWING 3
1
2
3
INPUT JACK OUTPUT JACK
BS170
DS G
1M 1M
5.1K
10µF 50V
100K
1 85
.1µF
400V
1
2
3
INPUT JACK OUTPUT JACK
BS170
DS G
1M 1M
5.1K
10µF 50V
100K
1 85
DRAWING 4
1 3
64
2
5
1 3
64
2
5