Aion Theseus Manuel utilisateur

THESEUS DUAL OVERDRIVE 1

PROJECT NAME

THESEUS

BASED ON

EFFECT TYPE

PROJECT SUMMARY

DOCUMENT VERSION

Analogman King of Tone

One of the earliest boutique “waitlist” pedals, this dual-channel drive is made up of two modified

Marshall Bluesbreaker circuits in series.

Dual-channel overdrive 1.0.0 (2023-02-02)

BUILD DIFFICULTY

Intermediate

This documentation is for the kit version of the project. If you purchased the PCB by itself, please

use the PCB-only version of the documentation instead. The circuit is the same, but the instructions

are completely different due to the specialized parts and assembly methods used in the kit.

IMPORTANT NOTE

THESEUS DUAL OVERDRIVE 2

TABLE OF CONTENTS

1Project Overview

2Table of Contents

3Introduction

4Packing List

5Packing List (Cont.)

6Tools Needed

7Component Identification

8Hardware Identification

9Overview

10 Resistors

11 Diodes

12 Sockets & ICs

13 Trimmers

14 DIP Switches

15 Capacitors (Non-Polarized)

16 Wire Headers

17 Capacitors (Polarized)

18 Footswitch PCB

19 Input/Output PCB

20 Enclosure Layout: Potentiometers

21 Enclosure Layout: LED Bezels

22 Enclosure Layout: LEDs

23 Enclosure Layout: Footswitches

24 Enclosure Layout: Main & Footswitch PCBs

25 Enclosure Layout: Input/Output PCB

26 Enclosure Layout: Finished Diagram

27 Final Testing & Assembly

28 Schematic

29 Full Parts List

30 Troubleshooting Information

31 Support & Resale Terms

32 Legal Information & Document Revisions

THESEUS DUAL OVERDRIVE 3

INTRODUCTION

If this is your first pedal, welcome to the hobby and thank you for choosing Aion FX. You’ve just joined

a community of over 40,000 people around the world with a passion for building homemade noise

machines using obsolete electronics technologies, and we’re glad to have you!

If you’ve done this before, it’s great to see you again and we’re confident you’ll find this build experience

an enjoyable one.

Aion FX kits are designed to empower anyone to build a high-quality pedal, no matter the skill level.

The pedalbuilding hobby has traditionally had a steep learning curve, but don’t be overwhelmed—we’ve

done all the hard work for you. All you need to do is follow these instructions and you’ll be on your way

to transforming your tone.

There are a few things to go over before you get started.

• You’re going to have to get your hands dirty—there’s no way around it. Nothing here comes

preassembled, and you’ll have to learn the skills to put it all together. This document will walk you

through everything you need, but be prepared to learn a few things along the way.

• This will take time. Plan on about two hours start to finish. It may take even longer if it’s your first

time building. Don’t rush it. If you find yourself getting frustrated or overwhelmed, take a break and

come back in a couple of hours or the next day.

• No direct technical support is offered. There are several DIY forums and Facebook groups with

thousands of members who enjoy troubleshooting and teaching. But please be sensitive to the fact

that the staff at Aion FX is minimal, and every minute spent helping individuals in private is time

that can’t be spent on new project development.

• There is no implied guarantee of a final product. Aion FX provides the ingredients and the recipe,

but you are responsible for putting everything together to make it work. We’ve tried to make the

process as clear and accessible as possible, but it must be expressly stated that purchasing the kit is

not a guarantee that you will end up with a working pedal.

It’s recommended to read through all of the instructions before you start, particularly if you’ve never

built a pedal before. If you familiarize yourself with the entire process ahead of time and you know what

the goal looks like, each step will make more sense.

Now, on to the fun stuff!

THESEUS DUAL OVERDRIVE 4

PACKING LIST

This is a list of all the parts that are included with the kit, grouped by value. For a list of all the parts

based on their PCB part numbers, please see page 29.

If you find that any parts are missing or damaged, please fill out the Missing Parts form.

Film Capacitors

NAME QTY

10n 8

22n 2

100n 2

1uF 2

Electrolytic Capacitors

NAME QTY

1uF 2

100uF 4

MLCC Capacitors

NAME QTY

100pF (marked “101”) 2

100n (marked “104”) 1

ICs

NAME QTY

JRC4580D 2

8-pin socket 2

Other

NAME QTY

Trimmer, 50k 2

DIP switch, 3-pos. 2

Resistors

NAME QTY

47R 2

1k 4

6k8 4

10k 2

22k 2

27k 2

33k 2

47k 4

100k 2

220k 2

1M 6

Diodes

NAME QTY

1N5817 1

1N914 4

BAS33 8

THESEUS DUAL OVERDRIVE 5

PACKING LIST (CONT.)

Potentiometers

NAME QTY

25kB 2

100kA 2

100kB 2

Dust cover 6

Knob 6

Mounting nut, potentiometer, 0.44" 6

Lock washer, potentiometer, 0.5" 6

Outer washer, potentiometer, 0.475" 6

Other

NAME QTY

LED bezel 2

LED, blue 1

LED, red 1

DC jack 1

Input/output jack 2

Mounting nut, I/O jack, 0.54" 4

Outer washer, I/O jack, 0.6" 2

Lock washer, I/O jack, 0.5" (thin) 2

Send/return jack, Neutrik NMJ6 2

Insulation washer, Neutrik NMJ6 2

Ferrule, chrome, Neutrik NMJ6 2

Enclosure 1

Enclosure screws 4

PCB, main circuit 1

PCB, footswitch 1

PCB, input/output/DC 1

Switches

NAME QTY

Stomp switch, 3PDT 2

Mounting nut, stomp switch, 0.6" 4

Lock washer, stomp switch, 0.6" 2

Dress nut, stomp switch, 0.77" 2

Wiring

NAME QTY

4-strand wire assembly, 60mm 2

6-strand wire assembly, 96mm 1

4-pin wire assembly header 2

6-pin wire assembly header 1

THESEUS DUAL OVERDRIVE 6

TOOLS NEEDED

SOLDERING IRON

Temperature-adjustable is

recommended. The optimum

soldering temperature is 700-725º

F (371-385º C) for leaded solder, or

750º F (400º C) for lead-free.

WIRE SNIPPERS

Also called nippers or wire cutters.

The Hakko CHP-170 is the best you

can get for less than $10.

SCREWDRIVER (PHILLIPS)

Used for the enclosure screws. Get a

powered driver if you’ll be building a

lot of pedals!

SOLDER

Preferably 63/37 or 60/40 leaded

solder. Lead-free is more difficult to

use, so if that’s the only type you can

get, it’s best to watch tutorials that

are specific to lead-free solder.

NEEDLE-NOSE PLIERS

These are used for bending leads on

components and other general uses.

Use the smaller type with a tip that’s

approximately 0.05” (1.25mm) wide.

FLAT SCREWDRIVER (SMALL)

This is used for tightening the set

screws on the knobs. The tip should

be no more than 0.1” (2.5mm) wide.

DIGITAL MULTIMETER (DMM)

Most cheap ones in the $10-30 range

are fine for what we’re doing. Make

sure it has audible continuity testing

(i.e. it beeps at the lowest resistance)

and transistor hFE measurement.

FLAT-NOSE PLIERS

Many general-purpose uses, but par-

ticularly tightening the nuts of pots,

switches and jacks. Quicker than

changing out sockets on a ratchet.

RUBBER BAND

Yes, a plain old rubber band. This is

used to tighten the dress nut to avoid

scratching or denting it (which can

happen with metal tools).

THESEUS DUAL OVERDRIVE 7

COMPONENT IDENTIFICATION

If you’ve never built a pedal before, you’ll need to know what all the components are. These are shown

actual size. (Not all of these types of components may be part of this kit.)

TRIM POTENTIOMETER

FILM CAPACITOR

SILICON DIODE

ZENER DIODE

LED

DC JACKWIRE ASSEMBLY HEADER

LED BEZEL

WIRE ASSEMBLY

ELECTROLYTIC CAPACITOR

IC OR OP-AMP

TANTALUM CAPACITOR

SCHOTTKY DIODE

IC SOCKET

RECTIFIER DIODE

TRANSISTOR OR JFET

Not polarized. Color may

vary by brand and type.

Some Schottky diodes

also look like this.

Polarized. The positive side

is marked.

Polarized. The negative side

is marked.

Some voltage regulators

also look like this.

Charge pumps and delay chips

also look like this. They may

have more than 8 legs.

RESISTOR

GERMANIUM DIODE

MLCC

Not polarized. MLCC stands for

“multi-layer ceramic capacitor.”

These are very fragile, so be

careful when handling them.

DIP SWITCH

The number of switch

positions may vary.

1 2

DIP

THESEUS DUAL OVERDRIVE 8

HARDWARE IDENTIFICATION

The hardware comes unassembled, so you’ll need to sort & identify each of the pieces. The diagrams

below are actual size, so you can set them against the printed page to identify them if needed.

I/O JACK

SEND/RETURN JACK

POTENTIOMETER

(SINGLE)

FOOTSWITCH

POTENTIOMETER

(DUAL)

MOUNTING NUT

CHROME FERRULE

MOUNTING NUT

DRESS NUT

OUTER WASHER

INSULATING WASHER

OUTER WASHER KNOB

LOCK WASHER

DIAMETER: 0.54” / 13.7mm

DIAMETER: 0.44” / 11.2mm DIAMETER: 0.5” / 12.7mm

DIAMETER: 0.6” / 15.2mm

DIAMETER: 0.475” / 12mm

DIAMETER: 0.5” / 12.7mm

DIAMETER: 0.63” / 16mmDIAMETER: 0.77” / 19.6mmDIAMETER: 0.63” / 16mm

THESEUS DUAL OVERDRIVE 9

PCB ASSEMBLY OVERVIEW

To begin, snap apart the main PCB and footswitch board and break off the tabs from each using needle-

nose or flat-head pliers. You’ll be left with the three PCBs shown above.

The general principle for PCB population is that you want to work in layers from shortest components

(i.e. lowest-profile) to tallest so that when the PCB is upside-down, everything is making contact with

the work surface and is held in place. Generally speaking, we want to populate them in this order:

1. Resistors & diodes

2. IC sockets & DIP switches

3. MLCC capacitors

4. Film capacitors

5. Electrolytic capacitors

THESEUS DUAL OVERDRIVE 10

RESISTORS

PART VALUE

R1 1M

R2 100k

R3 1k

R4 27k

R5 33k

R6 10k

R7 220k

R8 6k8

PART VALUE

R9 1k

R10 6k8

R11 1M

R12 47k

R13 47k

R14 1M

R15 100k

R16 1k

PART VALUE

R17 27k

R18 33k

R19 10k

R20 220k

R21 6k8

R22 1k

R23 6k8

R24 1M

PART VALUE

R25 47k

R26 47k

R27 47R

R28 47R

R29 22k

R30 22k

RPD1 1M

RPD2 1M

Using the parts list above, populate the resistors by pushing them through the holes and bending the

leads outward at an angle to hold them in place. Resistors are not polarized, so they will work in any

direction. Turn the board upside-down to keep the components held in place while you solder.

Don’t try to do all of the resistors at once. You’ll want to stop periodically flip the board and solder

everything, then cut the leads using the wire snippers to make room for more.

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