Fixing Up An Old Homebrew Rig -- Barebones Superhet and VXO 6 Watter

 

I'm not exactly sure why I pulled this old rig off the shelf, but I'll write up what I did -- I often use this blog as a kind of notebook.  I can look back and easily see what I did on my last encounter with the rig. 

The receiver is Doug DeMaw's Barebones (aka Barbados) Superhet.  This was my first superhet receiver. I built in in 1997.   The transmitter was my first real homebrew project -- it is the VXO 6 watter from QRP classics.  I built it in the Dominican Republic, probably in 1993 or 1994.  I built the power supply so that I could say that the entire rig is homebrew. 

This rig is getting a bit long in the tooth:   The receiver is built with 40673 Dual-Gate MOSFETs, an some of the transistor cans have gotten rusty.  The frequency readout on the receiver is the top of a coffee can fitted onto the reduction drive behind the tuning knob from a Drake 2-B (not MY 2B!). 

Here are two 2013 videos that I did on this receiver: 

https://soldersmoke.blogspot.com/2013/03/video-of-my-barebones-superhet.html

-- I put the crystal filter back in CW mode.  I had widened it so that I could listen to 20 meter SSB, but I decided to go back to its original configuration.  When I built the receiver in 1987, I didn't characterize the crystals -- I just used the capacitor values that Doug DeMaw had in his article.  I pretty much did that again this time, just putting caps that are close in value to what Doug had.  DeMaw used color burst crystals at 3.579 MHz.  So I guess this would be a GREAT receiver for the Color Burst Liberation Army!  

-- I used My Antuino (thanks Farhan!) to check the passband.  Here is what it looks like.  I just put the Antuino across the 10k resistors on either side of the input and output transformers.  The coil cores had become very loose -- I just tried put them in the right place.  I may need to put some wax in there to allow them to better stay in place. I think they could have used toroids instead -- that would have been easier. One of the transformer connections was open -- they don't work well that way,  once I fixed that, the passband looks like this: 

-- Each of the horizontal divisions is 500 Hz.  The passband is not pretty, but it is OK, and I  didn't feel like doing too much work on this to get it in better shape. 

-- The filter peak was a bit lower in frequency than expected.  I found that trimmer cap C3 in series with the BFO crystal would not allow me to lower its frequency sufficiently.  So I moved C3 to a position in parallel with the crystal.  With this mod, I could get the BFO frequency to 3578.69.  This produces a 690 Hz tone when the received signal is at the peak of the IF passband.  Opposite sideband rejection is quite good. 

March 2013 Rebuild of the VXO 6 watter

-- I didn't have to do any real work on the transmitter.  The RF amplifier in the transmitter had served for a time as the RF amp in by 17 meter DSB rig (I had added a bias circuit, which I removed when I put the amplifier back in Class C).  Some time ago I rebuilt the oscillator circuit (which had been literally cut off the board when I used the amplifier in the DSB rig). 

-- I did have to reconfigure the muting circuit -- the T/R switch in the transmitter switches the antenna and also -- through a two wire circuit -- cuts off 12 V DC to the transmitter when in receive mode. 

-- For sidetone I just put a small piezo buzzer through a 1k resistor between 12 V DC and the key line. 

It all worked fine -- I talked to three stations on the high end of  the 20 meter CW band. 

Exorcism Lite -- Spur Suppressed on 17 meter Transmitter -- Split TX/RX Station On The Air

I spent most of January in the tropics, away from my workbench.  This seems to have had a good effect on my 17 meter split TX/RX project.  As I was leaving, heading south,  I was thinking about several difficult options to deal with my spur problem (see previous blog posts). I thought about turning the transmitter into a transceiver by building a receiver board.   I thought about putting San Jian frequency counters on both the transmitter and the receiver, then doing a visual numerical "netting" by just putting the two devices on the same frequency (I actually ordered 3 San Jian counters).   The counter option was even more complicated than it at first seemed -- I would have to build a converter to shift the RX VFO frequency up.  VK2EMU suggested a tube type "Magic Eye" (interesting idea, but also complicated).   This was getting out of hand. 

When I got back home, I took a new look at the problem.   I decided to take one more shot at suppressing the 8th harmonic of the carrier oscillator.  I had already built a new oscillator and buffer using the circuit from Farhan's BITX20.  And I had put it in a metal box.  Now I decided to do three things: 

1) Tighten up the low pass filter at the output of the buffer by moving the cutoff frequency lower (to around 7 MHz) thereby getting a bit more suppression at 41 MHz

2) Try putting a series LC shunt circuit tuned to 41 MHz  at the output of the carrier oscillator (between the oscillator and the buffer). 

3)  Reduce the voltage to the oscillator/buffer.  I have this on a pot, so I can adjust it down to the point where the remnant of the harmonic is no longer audible, while keeping the main carrier osc signal sufficiently strong. 

It seemed to work.  I could now hear the desired frequency for spotting, without the confusing tone from the spur.  

Why had I been able to do this back in 2002 in the Azores using a simple trimmer cap to ground?  My guess is that I was using my Drake 2-B as the receiver.  The trimmer cap to ground may have reduced harmonic output.  And I was probably cranking back the RF gain on the 2-B to the point where I could hear the desired signal but not the remnants of the spur.  I have no RF gain control on the Barebones Barbados receiver that I am using in this project. 

So, what's the lesson from all this?  Well, if you are faced with a serious technical problem, and you find yourself considering complicated and difficult solutions,  go to the Dominican Republic for about a month (especially if it is January or February), and then take another look at the problem when you return.  If you are unable to travel this far or for this long,  taking a walk or taking a weekend break from a troublesome problem will likely have a similar mind-clearing effect. 

The video above shows part of a February 1, 2022 QSO with Gar WA5FWC using the split TX/RX 17 meter rig.  Gar is an amazing long-time SSB homebrewer who got his start with phasing rigs back in the day. 

Junk Box Sideband from the Azores (2004 QST Article)

About 20 years after I first built it, I find myself working on and using this SSB transmitter.    I recently added some impedance matching to the Swan 240 crystal filter;  several years ago I replaced the PA with a "JBOT" amplifier designed by Farhan VU2ESE.  I now have it on the air, using it with a highly modified Doug DeMaw, Barebones "Barbados" superhet  receiver. I had my first (recent!) QSO with this station yesterday, with Les 6Y6Y on the beach in Negril, Jamaica. 

More on this project in due course. Lots of soul in this machine. 

I'd forgotten about this article -- thanks to Pete Eaton for reminding me. Click on the images for a better look at the article. For an even clearer view, download the images and then open them on your computer. 

Michael Newton Hopkins, AB5L, Author of the FMLA series

Better than anyone else ever has, Michael Hopkins, in his fictional series about Frank Jones and the Five Meter Liberation Army, captures the spirit of homebrew radio.  There is just so much of us in those articles.  I read them some 20 years ago when they first came out; reading them again recently I appreciated them even more.  

Frank was a bit of a curmudgeon:  There are jabs at the appliance operators, Hiram Percy Maxim, hamfests, SSB, the Collins collectors, the QRP movement,  and even Electric Radio magazine.  Howard Armstrong makes an appearance, as do Carl and Jerry.  It all made me want to put a five pin SAW filter on my lapel.  

As I read, I thought about what a great writer Michael was.  When I Googled him, a few of the results led me back to  my own book.  I'd forgotten that Michael was in there, but he is.  On one page he advises me how to power my Mate for the Mighty Midget receiver without using a power transformer (a very Frank Jones approach).  On another page I note that Michael had sent me a kit for the Doug DeMaw "Barbados Receiver."  Wow, that was my first Superhet.  (I also have one that was built by Dale Parfitt.)  Most of the parts were put to use in other projects.  But I still have the board (see above).  Reminded that it came from Michael, I will now have to complete the construction.

Below is a nice article about Michael that appeared in the Flying Pigs newsletter. (Click on the images for an easier read.)   

The articles can be found here: 

http://soldersmoke.blogspot.com/2021/07/summer-reading-for-homebrewers-frank.html

Michael's 2005 Obituary:

https://obits.dallasnews.com/us/obituaries/dallasmorningnews/name/michael-hopkins-obituary?pid=14406223

Thank you Michael.  VIVA EL FMLA! 

A Lot of Soul in the Barbados Receiver

After a rather frustrating period working on the Hallicrafters S38-E, I decided to do something different, maybe work on something that isn't known as a "widow maker."    So pulled off the shelf an old Doug DeMaw Barbados Superhet Receiver.  "Barbados" sounds much nicer than "widow maker."  This design and this particular receiver have quite a history: 

-- DeMaw presented the receiver in the June 1982 issue of QST.  It uses six 40673 dual gate MOSFETS, an op amp for the audio, and a 250 Hz crystal lattice filter at 3.579 MHz using (YES!) colorburst crystals.  The local oscillator was a VXO. Doug's was for 20 meters, but his article provided a lot of info on how to put it on other bands.

-- I built one in 1997, building it for 20 CW.   That project is described here:

http://www.gadgeteer.us/RXHB.HTM

-- Sometime around 2000 I bought another one.  This one had been built on a FAR Circuits board by Dale Parfitt, W4OP.  Dale had used 5 MHz rocks for the filter and had used a varactor tuned circuit for the LO (with a DC-DC converter to increase the range).   I put it aside.  It sat on shelves in several countries for a number of years.  (I even have a THIRD one, a partially stuffed board that Michael Hopkins (the guy who wrote those great stories about Frank Jones coming back to life to retake the 5 meter band)).

-- I started working on it again around 2005. We were in London by then.  I put it on 17 meters using a capacitor-tuned VXO running up at around 23 MHz.   I did a quick and dirty broadening of the crystal filter by simply changing the capacitor values in the filter.  This worked, but obviously it needed refinement.  As I asked questions about this receiver, Dale Parfitt came to my rescue.  It took us both a while to realize that he was advising me on the receiver that he had built.  That was kind of cool.

-- I used the receiver with my first homebrew SSB transmitter.  I had them both running with separate VXO's, with crystals switched from the front panels.  I'm sure there were no other rigs like this on the air anywhere in the world.

-- By 2011 we were back in the US and I put my old homebrew SSB station back on the air.

-- In October 2014 I was building my first BITX rig.  I built it for 17 meters using a 23 MHz VXO.  I took the crystals out of the Barebones receiver.  Later that month I used an Arduino/AD9850 DDS arrangement as a digital crystal replacement: 

http://soldersmoke.blogspot.com/2015/01/digitizing-barebones-superhet.html

It worked, but it looked hideous.

-- By January 2015 I had learned a lot about how to characterize crystals and build filters.  I decided to take a shot at properly expanding the frequency response of the 5 MHz Barbados filter.  I measured the characteristics of the crystals and got the proper cap values for a 3 kHz filter.  When I tested it, the width seemed fine, but the ripple was more than I had expected.  Kind of disappointed I moved on to other projects.

-- Which brings us to today.  Escaping from the S38-E, I decided to put the Barbados receiver on yet another band.  With sunspot numbers in decline, I opted for 40.  And I wanted this to be an analog, L-C VFO project. No DDS, no PLL.  It would be all L and C for me, thank you! First I played around with the idea of running the VFO up at around 12 MHz, subtracting the 7 MHz sigs to get to the 5 MHz IF. But then I did a sweep of the filter.  First, there was a nice surprise -- the width AND the ripple were fine, just what I wanted (I must have had a measuring problem when I checked the ripple before).  And the skirt was MUCH steeper on the high side than on the low side.  This is why these filters are often called Lower Sideband filters.  You get better opposite sideband rejection if you use them as LSB filters.  

With the skirt situation in mind, I realized that running the LO at 12 MHz would not be a great idea. Our rule of thumb tells us that if we SUBTRACT the signal with the modulation from the signal without the modulation, we'll get SIDEBAND INVERSION.  So 7 MHz LSB would end up as 5 MHz USB.  Not great.  Plus, it is hard to get a VFO stable at 12 MHz.

So I opted to run the LO at around 2 MHz.  There would be no sideband inversion, and it would be easier to get the oscillator stable.   Wary of the threat of harmonics and spurs, I ran the receiver for a few days using an Arduino AD9850 at 2.125 MHz - 2.300 MHz.  It worked fine.

I now have the receiver running with a real Colpitts VFO.  The inductance is provided by an adjustable, shielded coil at around 1.5 uH (it was on the board) in series with a 3 uH toroid (type 6 yellow).  The feedback caps are at 2200 pf with a 1020 cap in series.  The main tuning cap is a small air variable with 73 pf max.  This only lets me tune about 40 kHz of the band, so, in a variation on the old Main Tune -- Bandspread technique, I have a rotary switch that adds capacitance in parallel with the main tuning cap.  I can now tune from 7.141 to 7.300.  The tuning rate is fine and I didn't have to mess with a reduction drive. 

More Barbados receiver blog posts here:

http://soldersmoke.blogspot.com/search?q=barbados

Kind of amazing that DeMaw designed this thing 34 years ago.  A lot of soul in this old machine.   

Doug DeMaw's Rigs Found, Donated to ARRL for Exhibit

http://www.arrl.org/news/museum-donates-doug-demaw-w1fb-homebrew-equipment

This is really good news (Thanks to Pete Eaton for the alert.)

I wonder if the Barebones "Barbados" Superhet was in this batch.

We KNOW where that Tuna Tin 2 is....  

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Broadening the Barebones Barbados Receiver

I've been working on the crystal filter of the Barbados Barebones Superhet receiver.  This was designed by Doug DeMaw in 1982.  This one was built by Dale Parfitt W4OP and then repeatedly modified by me.  It is now on 17 meters with a crystal-switchable VXO.    Earlier I had made a very crude attempt to broaden the filter from its original very narrow CW configuration.    This week I did this again, but this time I actually characterized the crystals and used Wes's LDA and GPLA software (from EMRFD) to design the filter.  

I played with the capacitor values and finally got the 3 kc bandwidth I wanted, but I'm having trouble getting rid of the ripple.   I know this is dependent on the impedances at the two ends.  The programs say I need 2000 ohms.   

I'm kind of puzzled about how Doug DeMaw did this with his original design.  For his crystals and his 250 Hz (!) bandwidth he said he needed 450 ohms.   He used 4.7:1 turns ratio transformers at either end and said that by putting 10k resistors across these transformers he got the needed impedance.  I can see how this would work looking into the gate of the 40673 IF amp, but looking back at the drain of the 40673 mixer, I'm not so sure that that would yield 10k. (See schematic below.)

But who am I to doubt Doug?   So I assumed he was correct about the 10K and I re-wound the transformers with a 2:1 turns ratio, thinking that would get me closer to the needed 2k.   But the ripple is still there.  I guess I could use a return loss bridge at this point... 

I don't know whether this is worth messing with anymore.  The receiver sounds nice.  The 3kHz bandwidth gives it a nice sound, and the ripple doesn't seem to be noticeable  That FAR circuits board is tightly packed and difficult to work with.  So, should I leave good enough alone, or should I proceed with fanatical ripple eradication.  Any advice?

BTW:  Why is it that receivers always seem to sound better when opened up (as above) on the workbench?  

 

 


Our book: "SolderSmoke -- Global Adventures in Wireless Electronics" http://soldersmoke.com/book.htm Our coffee mugs, T-Shirts, bumper stickers: http://www.cafepress.com/SolderSmoke Our Book Store: http://astore.amazon.com/contracross-20

Edgy Skimmer Antenna

For the last few days I've been hanging out on 20 meter CW, 14.050 - 14.060 MHz, using my re-built W1VD/Barbados rig.   I've had some great contacts, but almost as  much fun is watching the Reverse Beacon Network to see who is hearing my calls.   WA7LNW is one of the "skimmers" that most consistently picks up my signal.  One look at the picture above explains this.  The receive antenna for his skimmer rig IS ON THE EDGE OF THIS CLIFF!   Jack has one of those dream jobs for a radio amateur:  he works at that amazing location, testing ejection seats for jet aircraft.  More great pictures here: 

http://www.dxwatch.com/qrz/lookup.php?c=rbn/WA7LNW

Thanks for the reports Jack!

Our book: "SolderSmoke -- Global Adventures in Wireless Electronics" http://soldersmoke.com/book.htm Our coffee mugs, T-Shirts, bumper stickers: http://www.cafepress.com/SolderSmoke Our Book Store: http://astore.amazon.com/contracross-20

Richard's Rip-Van-Winkle Barbados Rig

Dear Bill,

Thank you for taking a few minutes to read my email. I recently found your blog and enjoyed reading the entries.  However, the most interesting and exciting article I discovered was your "Homebrew Radios in the Age of the Internet." The article reminded me of a project started 30 years ago this month and placed in a box in the attic to wait until I could return to it.
Thirty years of health care management work filled the interim.

The project is the 8P6 Hamcation rig by W1FB from QST of June and November 1982!

I searched through the cob webs in the attic and found that all the boards are completed and I even fabricated a case. The original QST's were there too! In response to a (somewhat strong) suggestion from my wife to "get a winter project going", the rig is back on my retirement work bench. Wahoo.

Progress to date has been instructive and fun. The boards are all cleaned, checked, and 95% wired together in the case and working. I attached 2 photo for your pleasure because you wrote specifically about the receiver in some blog posts.

This is where I am scratching my head. As you say in the article, "receivers are tough". I am confused and a bit frustrated about the correct procedure and sequence to correctly align the Barebones superhet. I can already hear stations and the noise level is acceptable. But I am not quite sure how to proceed in peaking up the receiver (hit a plateau?) Any suggestions for a newly retired ham now with the time to get back to the bench?

Thank you very much for your kind comments and interest in my project.

73's
Richard
WB2PEF
Cherry Valley NY

Wow, what a cool resurrection project!   I recognize both the receiver and transmitter boards.   The RX is clearly DeMaw's Barebones Superhet on a FAR Circuit board.  I am listening to one of those AS I TYPE.  Mine was put together by Dale, W4OP, and currently inhales on 17 meters.   The TX board is what became known as the VXO 6 Watter.   It was (I think) designed by W1VD, and appears in the ARRL book "QRP Classics."   This was my first really successful homebrew rig -- I built that transmitter in the Dominican Republic  in 1993.   I still have most of the board, and the 20 meter Barebones RX that I used with it.   Richard's message makes me want to put this old gear back on the air. 

I hope Richard will send us an update on his Barbados revival project.

I'm sure Doug DeMaw would be very pleased to know that his projects are still providing radio amateurs with a lot of fun and inspiration.


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