Update - January 2012 - Yes, I really did once upon a time build a Jammer by hand.
How I have better ways to do it. See recent posts. Ken.
I've documented how useful a jammer is elsewhere . In short, it's like a super-improved piano, a 2.0. version.
Riddle: How do you make a 4-row hexagonal-key instrument from a 2-row piano-key one?
Answer
: You cut it in half and fold the keys back under!
Amazingly Simple, ain't it?
Expand the picture to the left
for the details.
I’ve made two, the first, a light wear-able version:
and the second, a stand-top version:
The first was naturally harder to build. Design improved with the second; it can be made by anyone with basic carpentry skills (no electronics skills needed).
Update: I'm seriously investigating making modified keys and the colored key-caps (as seen in the photo to the right) made. I've created prototypes, next the question is the cost. If so, I can create a simple conversion kit. Drop me a call here if interested.
Here goes a basic summary (if you find yourself confused contact me, and I’ll happily elaborate).
Background (optional reading):
A typical electronic keyboard has 2 parts, one is the music control electronics, and the second the key holder assembly itself.
I have examined just 3 keyboards, A Yamaha DjX, a Technics P50 and a M-Audio 88es, but I suspect most are pretty similar.
The key board electronics is on two loooong printed (Image) circuit boards (PCB) clamped into the key assembly. The two boards are connected to each other by a single 6-inch, 12-lead wire, and one of the boards in turn connected by a 10 inch or so, 6-lead connector to the controller. The controller in turn has connectors running to switches mounted on the case.
Incidental details on how the keyboard works: each long PCB has clamped onto it a bunch of rubber buttons which make a little dome about 2-3 mm over the PCB. These buttons are depressed when the plastic keys of the keyboard assembly are pushed down (I'm not sure what makes them happy).
The underside of the little dome buttons, the part clamped to the PCB, has a little bit of conductive black graphite paint on it, and when it hits the PCB, it closes a circuit, and the circuit generates a signal that the controller interprets.
On the Technics and M-Audio keyboard, each key has two buttons it depresses, presumably at slightly different times to denote a key's velocity. The Yamaha has a double contact set within each button and the contacts are of slightly different length, thus denoting the key's velocity.
The important thing here is that you don't need to know further detail on how it works, or electronics. Your can mod an existing keyboard slightly.
In my first design, I used just the PC boards and the rubber buttons, and rebuilt the whole key holder assembly. For the second one I borrowed a simple idea from a nice guy in Chile and added to it.
List of materials
- A keyboard to cannibalize - I recommend the M-Audio Keystation 88es (now $300US), but Keystation 61es ($200) might do the trick. This is an excellent, rugged keyboard, without flashy buttons that are useless to our purposes. Critically, it is also USB powered – it can work with only a laptop.
- A laptop that can run Max/Msp or some other midi remapping software and the instrument samples you desire. If you are buying one, check that it has enough volume.
If your laptop is quiet, a small pair of battery-powered “iPod” speakers works well.
- Some wood for the box to contain it. I used 8 feet of 3” hemlock coving.
- Clear plastic or plywood sheet about 3 mm thick for the base –
I suggest a piece from a vinyl window. One should be able to get this from a glass window shop.
- 133 keycaps – allow extra 10 for wastage - a set of 1” or 1 1/16 plastic disks.
- double–sided tape. to attach the keys caps were attached to the key-bases.
- 2 spray cans of black paint, or one black and one varathane varnish for a more exotic pearly effect
- Model cement to stick wood to plastic (Weldon #16 worked well)
- Wood glue
Tools
- Drill press with depth control
- Drill bits in 1/64" gradations
- Work shop Disk Sander is handy – these are $50-70 and this is a good time to get one.
- A fine-tipped felt pen to mark up the plastic or wood base.
- Table Saw to make the keys (a hand saw may do)
Software
- Needed is some way to remap the keys to different notes. I used MAX/MAP, an excellent but expensive program @ $500 (I have lots of uses in mind for it, so felt it's price justified). One might be able to use Java, or in a pinch, I will compile my Max version and send you a runtime exe.
- A nice instrument pack – I have Garritan’s GPO ($200), I have also heard that the MODARTT Pianoteq piano emulation package (Mac/Win) works well.
1. Preparing the keyboard
1. Before proceeding, plug in the keyboard into your desktop or laptop and confirm that it works before you start modding it. This will greatly ease your mind as you work.
2. Take apart the keyboard
, note that you need to keep only the screws that hold the keyboard assembly to the shell, and the ones that hold the switches, volume control and pitch bend wheels to the shell.
3. Unplug the electronics from the keyboard assembly and put them in Ziploc bags and set them aside, safe from damage.
4. Discard the plastic cover, except for the small area that the controls and wheels mount on. Roughly saw that out (you will trim it down later) and keep it with the electronics.
5. Saw off the excess part of the white keys. I just left the keys mounted on the assembly and taped the assembly with wood and masking tape so the keys could not move and the plastic chips would not get into the workings of the key assembly (some did anyway). I then just passed it through the table saw several times, cutting through the white keys a groove a ¼ inch (3-4 mm) deeper each time (easier on the nerves, less risk, and avoided melting plastic). The cut was made about 1/8 inch (2 mm) beyond the tip of the black keys.
Note: a better way to do this would be to make new wooden keys with the right shape, (or have them pressed out of plastic should we have enough demand). I will do this for my next version. If you are interested, I’ll tell you how to do it (basically make a block of wood with the right cross-section, then slice off keys, drill 2 holes) you can make several while you are at it (very little extra work) and we will trade favours.
6. Level (top) the black keys so they are flush with the white keys. I did this by taking off each black key and clamping it into a piece of wood that I cut out / grooved to hold the black key and pass through the table saw correctly. This was slow and some needed building up and trimming to make them flush.
I suggest instead fixing the black keys so they can’t move and turning the key assembly sideways (on edge) and using the saw blade to trim off the top of the black keys.
7. Remove the wrapping and vacuum off the keys thoroughly.
8. Look over the keyboard assembly and find the place where the two printed circuit boards (PCBs) abut; this is where the keyboard will be split. Mark this point on the steel rails that make the bottom of the keyboard rigid (the M-Audio keyboards are definitely good units), that is mark the rail’s Front-left, Front-right, Back-right, Back-left sections. Unscrew the rails and saw them at the marked point.
9. Remove some keys around the PCB abutment point (I used a small flat-bladed screwdriver to gently lift the spring out of the slot, then inserted the screwdriver into the fulcrum access hole/attachment point – generally a gentle twist disengaged the catch.
10. disconnect the little cable connecting the two PCBs together & tape the floppy end down
11. with a fresh, high quality (the top part is steel – remember this is a good keyboard) blade, hack-saw the keyboard into 2 parts.
You are done the demolition. From here on it’s all building. I'm out of time, but here's a summary:
- Cut a mounting-board (dimensions to be posted later).
- Mount the key-assembly halves on it, facing each other and almost touching. Use the rails to determine where to place the holes.
- Tilt them at a 10-degree angle to each other. this is to stop the pinching one would otherwise get. I used the back-rail to prop it up, plus a little extra.
- I suggest re-drilling the black keys spring holes a bit deeper. You need to hold the keys in a clamp to do this (otherwise they will jump out the side slot). Cut them to the same extension (Not the same depth) as the white keys. make all the hole to the exact same depth. Consider also doing the white keys down a bit, 2 mm (1/8 inch), other wise they are a bit firm.
- Cut a wedge of wood for the key-posts at 10 degrees, then slice it in three, one stick for each post-key height, then cross-cut the sticks to the exact width of a key. This gives you the key-posts.Through the magic of designers luck
, this works out well.
- Mount the key-posts with wood-to-plastic glue; Weldon #13 worked well.
- Make or buy the Key-Caps, I used 1/8 inch plastic sheets, cut to a hex shape, then shaped and coloured. this worked well, but took more time than all the rest of the work.
I suggest seeing if you can get 1-inch plasitic disks.
- Stick them on with double-edged tape (use the best)
- Make the protective cover (dimensions to be added here)
- Paint it all.
- Mount the electronics.
- plug it in.
- I'll send you a run -time to map the keys, as shown:
That's all for now - if you want to build your own, post a comment, and I will gladly add detail.
====================================
Here's the end product to the left.
Currently the pitch-bend and mod wheels are hidden. I plan to made them into thumb controls.
The extra keys at the sides (one PCB was 10 notes longer than the other, so there was overhang) are octave-shifting function keys, used to make it pretend to have more rows and keys. In effect I have a 96-key keyboard that pretends, when needed, to be two keyboards, one for each hand. This all is documented here.
The blue-black keys in the center divide the two sides of the instrument, and are dynamically assigned to whichever hand is playing near them, see Colouring. The coloring pattern was an educated guess, but it seems I hit true gold.
With the special function keys, it's easy to play in any key.
Recent Comments