Colour Duo Assembly Guide
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Table of contents
- Required Tools
- Optional Tools
- Component Sorting Sheet
- I/O Board Assembly
- I/O Board Resistors (Bag 1)
- Bend Resistors
- Sort Resistors
- Place Resistors
- Solder Resistors
- Trim Resistors
- I/O Board IC, Transistors, Caps, Diodes (Bag 2)
- Populate Transistors
- Tape and Solder IC Sockets
- Place ICs in Sockets
- Populate Bypass Capacitors
- Populate Diodes
- Populate Small Capacitors
- I/O Board Connectors (Bag 3)
- Populate Board-to-Board Connectors
- I/O Board Large Capacitors, Inductors, and Relay (Bag 4)
- Populate Relay
- Populate Inductors
- Populate Large Capacitors
- Jacks (Bag 5)
- Populate TRS Jacks
- Populate XLR Jacks
- Drawer Assembly
- Active Switch Parts (Bag 6)
- Populate Resistors
- Populate Diode
- Populate Relay
- Install Lightpipe Switch Cap
- Populate Switch
- Populating the Channels
- Drawer Resistors (Bag 7)
- Sort Resistors
- Populate Resistors
- Drawer ICs and Colour Sockets (Bag 8)
- Populate Colour Sockets
- Populate IC sockets
- Populate Diode Bridge
- Populate ICs
- Drawer Capacitors and Diodes (Bag 9)
- Populate Bypass Capacitors
- Populate Diodes
- Populate Remaining Small Capacitors
- Drawer Large Capacitors (Bag 10)
- Populate Large Capacitors
- Populate Bug Fix Capacitors
- Drawer Connectors, Switches, and Sockets (Bag 11)
- Populate Board-to-Board Connector
- Install Switch Caps and Populate Switches
- Quick Question
- Populate Header Sockets
- Populate Potentiometers
- Drawer Daughter Board Parts (Bag 12)
- Populate Resistors
- Populate Header Pins
- Install Switch Caps and Populate Switches
- Chassis Assembly
- Chassis Fasteners (Bag 13)
- Insert Drawer Rails
- Fasten IO Board to Case
- Install Nut Plates
- Install PCB Support Brackets
- Mount Daughter Boards
- Install Lid
- Install Rack Ears (Optional)
- Apply Rubber Feet (Optional)
- Front Panel (Bag 14)
- Fasten Nuts to Pots
- Set Pots to Middle Position
- Fasten Knobs to Pots
- Insert Drawer into Case
- Final Checks
- Optional: Run Audio Tests
- Finished!
- Help Us Improve
Thank you for purchasing a Colour Duo!
The Duo is intended for intermediate builders. If you have built a 500-series module or several guitar pedals before you should have no problem with the Duo. However, keep in mind it's a big kit! There are hundreds of parts to place, so plan to split the building over several sessions.
Required Tools top
Soldering Iron
We recommend an adjustable-temperature station, such as the Weller WLC100.
Solder
You can use 60/40 "leaded" solder or lead-free. We recommend 60/40 because it flows better and is easier for beginners to use.
Wire Cutters
You'll need a pair of good "snips" for cutting of the excess leads after soldering.
Optional Tools top
Multi-meter
If you run into problems, a multimeter can come in handy. You can also use it to sort resistors.
Tape
A bit of clear tape will help hold some tricky components in place for soldering.
Desoldering Pump
If you accidentally solder something in the wrong place, a desoldering pump can save the day.
Component Sorting Sheet top
To identify and keep track the resistors, download and print the Component Sorting Sheet (PDF).
I/O Board Assembly top
The Colour Duo is split into two sections, the I/O Board and Drawer. In this guide we'll build the I/O Board first and then the Drawer.
Duo IO PCB Interactive Build MapI/O Board Resistors (Bag 1) top
Bend Resistors top
Bend the resistor leads 90 degrees at the body so they can be inserted into the PCB.
Parts in this step: Refer to the component sorting sheet.
Sort Resistors top
Resistor sorting made easy! Enter a value to find the color bands, or enter your color bands to find the resistor’s value. Type in the value of the resistor you need and this tool will show you the corresponding color code.
Place Resistors top
Place the resistors into their respective positions on the PCB. As you place each resistor, bend its leads against the bottom of the PCB so that it stays in place during soldering.
Solder Resistors top
Solder the resistors to the PCB. Observe good soldering technique: heat the pad and lead for 2-3 seconds, apply a small bit of solder, and continue to heat the pad for another 2-3 seconds. The finished joints should be shiny and should have just enough solder to cover the pad entirely.
Trim Resistors top
Use clippers to trim away the excess leads. Clip as closely as possible to the joint without clipping the joint itself.
I/O Board IC, Transistors, Caps, Diodes (Bag 2) top
Populate Transistors top
There are two important things to note about the transistors. First, one side of the body is flat while the other is round. And second, one is a BC327 (black top) while the other is a BC337 (silver top).
Place the BC327 in Q1 and the BC337 in Q2. Place both of them so that the shape of the body matches the shape on the circuit board. Double check the positions and orientation, then solder and trim.
Parts in this step:
Q1
BC327 transistor
Q2
BC337 transistor
Tape and Solder IC Sockets top
Insert the IC sockets so that the notches on the sockets align with the markings on the PCB. Secure in place with tape. Then flip the PCB over and solder in place. Remove the tape.
IC1, IC2
IC socket (x2)
Place ICs in Sockets top
The leads of the ICs must be slightly bent to fit perfectly into the sockets. For each IC, press one row of leads against a flat surface until they form a 90-degree angle with the body of the IC. Then do this for the other row.
IC polarity is indicated by a dot or notch on one side of the body. Align this side with the notch in the sockets. Place all of the ICs in this direction, and press them completely into the sockets.
IC1, IC2
1256 line receiver (x2)
Populate Bypass Capacitors top
Populate the yellow .1uF capacitors in the positions marked CB, as well as C10 and C11. These capacitors are not polarized and can therefore be installed in either direction.
CB1-CB4, C10, C11
.1u ceramic cap (x6)
Populate Diodes top
Place each diode so that the line on the component matches the line on the PCB. Double check the orientation, then solder and trim.
D1
1N4004 diode
D2
5.6v zener diode
Populate Small Capacitors top
Place the smaller capacitors in their respective places. These capacitors are not polarized and therefore can be placed in either direction. Solder then trim the leads.
C2, C3, C6, C7
470p caps
Markings: 471
C4, C8
47p caps
Markings: 47j
I/O Board Connectors (Bag 3) top
Populate Board-to-Board Connectors top
Place the 32-pin connectors and fasten them with the included nuts, washers, and screws. The washers should between the bottom of the PCB and the nuts. Then solder and trim.
CON1A, CON2A
Board-to-board connector (x2)
CON1A, CON2A
3-48 Screw (x4)
CON1A, CON2A
Nylon washer (x4)
CON1A, CON2A
3-48 Nut (x4)
I/O Board Large Capacitors, Inductors, and Relay (Bag 4) top
Populate Relay top
Place the relay and bend some of the leads against the bottom of the PCB to hold it in place. Then solder and trim.
U1
24V relay
Populate Inductors top
Place the inductors in their positions, solder, and trim. Inductors are not polarized.
L1-L3
470u inductor (x3)
Populate Large Capacitors top
These capacitors are polarized, so they must be placed in a certain direction. The positive lead is slightly longer, while the negative lead is marked with a stripe on the body of the capacitor. Place the capacitors with the positive lead in the pad next to the "+" marking on the PCB. Double check their orientation, then solder and trim.
C1, C5
100u cap (x2)
C9, C16
100u/63v cap (x2)
C12-C15
2200u cap (x4)
Jacks (Bag 5) top
Populate TRS Jacks top
Place the TRS jacks. Hold them in place with tape or by bending the leads, then solder and trim.
J1, J5
TRS jack (x2)
Populate XLR Jacks top
Place the XLR jacks. Most will snap in place, but you may need to use some tape if they fall out before soldering. Solder the jacks but do not trim the leads.
J2, J6
3-pin XLR male jack (x2)
J3, J7
Combo jack (x2)
J4, J8
3-pin XLR female jack (x2)
J9
5-pin XLR female jack
J10
5-pin XLR male jack
Drawer Assembly top
Active Switch Parts (Bag 6) top
Populate Diode top
Place the diode so that the line on the component matches the line on the PCB. Double check the orientation, then solder and trim.
D3
1N4004 diode
Install Lightpipe Switch Cap top
Position the lightpipe switch cap so that the flat surface faces the bottom of the switch. Then press the cap onto the switch until it snaps into place.
Lightpipe switch cap
SW4
DPDT switch
Populate Switch top
Place the switch and use a small screwdriver to bend a couple of the leads against the bottom of the PCB. Solder and trim.
Populating the Channels top
Since channels 1 and 2 of the Duo are identical, the steps below are written for just one channel. The kit bags are also split up by channel, so there are two of each bag for the following steps. It’s up to you whether you want to build one channel at a time or both at the same time. If you choose to build them one at a time, repeat steps 7-12 for each channel.
Drawer Resistors (Bag 7) top
Sort Resistors top
Here's a link to that same resistor tool from above: Resistor Calculator
Parts in this step: Refer to the component sorting sheet.
Drawer ICs and Colour Sockets (Bag 8) top
Populate Colour Sockets top
Flip the PCB over and place the 8-pin Colour sockets in their positions. Solder one leg of each socket from the bottom to hold them in place, then flip the PCB over and solder all of the joints. Make sure that you have placed the sockets on the underside of the PCB before soldering!
CON6-CON8
Colour socket (x3)
Populate Diode Bridge top
Place the diode bridge, matching the labeling to that on the circuit board. Bend the leads against the bottom of the pcb, then solder.
BR1
Diode bridge
Populate ICs top
Place the ICs in their sockets as you did before, playing close attention to their orientation. Note that some NE5532 ICs have a dot on the body to indicate pin 1 instead of a notch. In this case, orient the ICs so that the dot on the IC aligns with the notch on the IC socket.
IC1
1512 mic preamp
Markings: THAT 1512
IC2-IC5
NE5532 opamp (x4)
Markings: NE5532P
Drawer Capacitors and Diodes (Bag 9) top
Populate Bypass Capacitors top
Populate the bypass capacitors as you did before.
CB1-CB10
.1u ceramic cap (x10)
Populate Diodes top
Populate the diodes as before, paying close attention to the black lines for orientation.
D1, D2
1N914 diode (x2)
Populate Remaining Small Capacitors top
Place the remaining capacitors in their respective places. As before, these capacitors are not polarized.
C4
82n cap
C6-C8
22p cap (x3)
Drawer Large Capacitors (Bag 10) top
Populate Large Capacitors top
Populate the large capacitors as you did on the IO board. Remember that these are all polarized and must be placed in a particular direction.
C1, C2
100u/63v cap (x2)
C5, C9
100u cap (x2)
C3
3300u cap
Populate Bug Fix Capacitors top
These two capacitors have been added to the kit to fix a bug where, in rare cases, IC1 will fail when the drawer is plugged and unplugged.
Before placing the capacitors, bend their leads so that they have approximately the same spacing as the distance between the +16v, Gnd, and -16v test points near U1. Then place the capacitors in the test points with the positive lead of in +16v, the negative lead of the other in -16v, and the remaining leads of both in Gnd. Solder and trim the capacitors.
N/A
220u cap (x2)
Drawer Connectors, Switches, and Sockets (Bag 11) top
Populate Board-to-Board Connector top
Place the 32-pin connector and fasten it with the included nuts, washers and screws. The washers should between the bottom of the PCB and the nuts. Then solder and trim.
CON1B/CON2B
Board-to-board connector
CON1A, CON2A
3-48 Screw (x2)
CON1A, CON2A
Nylon washer (x2)
CON1A, CON2A
3-48 Nut (x2)
Install Switch Caps and Populate Switches top
Press the caps onto the switches. This may require a bit more force than you’d expect.
Place the switches and use a small screwdriver to bend a couple of the leads against the bottom of the PCB. Solder and trim.
Switch cap (x3)
SW1-SW3
DPDT switch (x3)
Quick Question top
Populate Header Sockets top
Since these sockets will mate with pins on the daughterboard, it’s important to mount them exactly perpendicular to the circuit board. Our preferred technique for this is as follows:
- Solder a single pad in the middle of the header’s footprint
- Place the header and press gently against the solder joint, while heating the edge of the soldered pad
- After the solder liquifies and the header snaps into place, remove the soldering iron and hold the header in place until the solder cools (about 5 seconds)
- Now solder the rest of the pins of the header from underneath
CON3, CON4
12-pin socket (x2)
CON5
6-pin socket
Populate Potentiometers top
Pay close attention to the values marked on the back when placing the potentiometers (pots). Place them, then double check the values on the pots against those on the PCB. Bend two leads of each pot against the PCB, then solder and trim.
VR1
C1k pot
Markings: C1k
VR5
B10k pot
Markings: B10k
VR2, VR3, VR4, VR6
B20k pot (x4)
Markings: B20k
Drawer Daughter Board Parts (Bag 12) top
Populate Header Pins top
As with the header sockets, these pins must be perpendicular to the board to mate correctly. Follow the same technique:
- Solder a single pad in the middle of the header’s footprint
- Place the header and press gently against the solder joint, while heating the edge of the soldered pad
- After the solder liquifies and the header snaps into place, remove the soldering iron and hold the header in place until the solder cools (about 5 seconds)
- Now solder the rest of the pins of the header from underneath
CON3_DB, CON4_DB
12-pin header (x2)
CON5_DB
6-pin header
Install Switch Caps and Populate Switches top
As you did before, position the lightpipe switch cap so that the flat surface faces the bottom of the switch. Then press the cap onto the switch until it snaps into place. Also install the black switch caps on the remaining switches.
Then place and solder all the switches.
Switch cap (x2)
Lightpipe switch cap (x4)
SW1_DB-SW6_DB
DPDT switch (x6)
Chassis Assembly top
Chassis Fasteners (Bag 13) top
Insert Drawer Rails top
Position the drawer rails on the inside of the case with the wider opening facing the front of the case. Then snap them into the holes indicated above.
PCB rail (x2)
Fasten IO Board to Case top
Mount the assembled IO board to the case. You will need to tilt it slightly to get the PUSH tabs of the XLR jacks through the holes first. Then fasten the nuts and washers to the TRS jacks, and screw in the mounting screws for the XLR jacks.
XLR screw (x16)
Install Nut Plates top
Place each nut plate behind one of the flanges at the front of the case, so that the holes line up with those on the flange. Then fasten them to the case with the included screws.
Nut plate (x2)
Nut plate screw (x4)
Install PCB Support Brackets top
Place each L-bracket over the pots of the Colour section. Check that the standoffs on the brackets align with the holes in the PCB. Then fasten the brackets to the motherboard via the screws and standoffs. Use standoffs for the three holes closest to the front of the circuit board, and screws for the rest.
PCB bracket screw (x8)
Standoff (x6)
Mount Daughter Boards top
Plug the daughter boards for each channel into the two sets of header sockets. Then screw them to the support standoffs.
PCB bracket screw (x6)
Install Lid top
Place the lid on the case with the countersunk side facing up. Then screw it to the case.
Lid screw (x7)
Install Rack Ears (Optional) top
If you plan to use your Duo in a rack, screw the rack ears to the case.
Rack ear screw (x6)
Apply Rubber Feet (Optional) top
If you plan to use your Duo on a desktop, you may choose to apply the rubber feet to the bottom of the case. Keep in mind that you will need to remove them later if you want to use the Duo in a rack with another unit directly below it.
Rubber foot (x5)
Front Panel (Bag 14) top
Fasten Nuts to Pots top
Place the front panel over the pots and switches (yes, this might be the trickiest part of the build). Place washers over the pot shafts, then screw on the nuts. Note that depending on variations in the length of the threads on the pots and nuts, you may not be able to fit the washer under the nut. In this case, just leave the washer off and fasten the nut directly to the panel.
Pot washer (x12)
Pot nut (x12)
Set Pots to Middle Position top
To prepare for adding the knobs, set all the pots to the middle position (10 clicks in).
Fasten Knobs to Pots top
Place the wider, skirted knobs on the two preamp gain pots, and the non-skirted knobs on the rest of the pots. Orient all of them so that the indicator line points precisely to the 12 o’clock position. Then fasten the knobs to the pot shafts by tightening the set screws with the included hex wrench.
Skirted knob (x2)
Non-skirted knob (x10)
Insert Drawer into Case top
Insert the drawer PCB into the PCB rails, then slide the assembly into the case. There should be some resistance at the end when the board-to-board connectors mate. Then fasten the front panel to the case by tightening the thumb screws.
Final Checks top
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Capacitor orientation: Is the stripe on the cap on the opposite side from the "+" marking on the PCB?
-
Diode orientation: Do the stripes on the diode match those on the PCB?
-
IC orientation: Does the dot/notch on the IC align with the notches on the socket and PCB?
-
Resistors: Are all the resistors in the correct positions?
-
Transistor orientation: Does the shape of the transistor match the outline on the PCB?
-
Soldering: Is every solder joint shiny and clean? If one is cloudy or misshapen, try reheating it for 8 seconds and adding a tiny bit more solder.
-
Trimming: Are all of the excess leads trimmed down as close to the joint as possible?
Before you wrap up, check the following things:
Optional: Run Audio Tests top
If you're unit powers up and passes audio fine, most likely it's functioning exactly as it should. But if you want to really be sure, follow the steps in this video to test your Duo with the free software Room Eq Wizard (REW) and your interface:
Colour Duo Audio Test Process (YouTube)
If you are unfamiliar with the software, please watch our series of videos on measuring gear with REW:
Finished! top
All good? Congrats on finishing your build! Have a question or problem? Drop us a line.
