Ortho Snap-Part PCB Prep

Start by removing the top and bottom railing bits from both sheets. Use some pliers to gently bend at the perforation until the extra material snaps off.

Remove the 5th row from the two sheets using pliers to create two sets of 4x6 PCBs that look like the image below in the wiring section. (That's 4 rows, 6 columns).

Clean the edges from the top and bottom of the PCB using sandpaper or a metal file.

Wire PCBs

Start by wiring up the two 4x6 PCBs together. Use short wires, about 1 inch (25mm), connect the ROW, VIN, Ground(GND) and NeoPixel data OUT/IN pins.

Wiring The KB2040

Place the KB2040 microcontroller in the center above two 4x6 PCBs. Create wires with appropriate lengths for VIN and GND pins from right side PCB to the KB2040. Solder the wires to the pins. Then, solder the VIN wire to the RAW pin and GND to GND.

Create a wire with an appropriate length for the first NeoPixel LED (the top right) to connect to the MOSI pin on the KB2040. Solder the wire from the NeoPixel Data In pin to the MOSI pin on the KB2040.

Create four wires, with varying lengths, to connect the rows to the accompanying pins on the KB2040. Solder the wires, going from top to bottom, to the D6, D7, D8 and D9 pins respectively.

Create 6 wires, with varying length, to connect the columns on the right-half PCB to the accompanying pins on the KB2040. Solder the wires, going from left to right, A3, A2, A1, A0, CLK, and MISO pins.

Create 6 more wires, in varying lengths, to connect the columns on the left-half PCB to the accompanying pins on the KB2040. Solder the wires, going from left to right, TX, RX, D2, D3, D4, and D5 pins.

Install KB2040 Holder

Orient the KB2040 with the 3D printed holder. Then, insert the board at an angle so the edge of the PCB fits under the corner clips.

Slightly flex the holder to allow the other side of the PCB to fit under the clips.

Install NeoKey Mount

Orient the NeoKey PCBs with the 3D printed mount. Slide the mount in between the KB2040 mount and the NeoKey PCBs.

Line up the KB2040 holder mounting holes with the accompanying holes on the NeoKey mount.

Insert and fasten 2x M3 x 4mm long machine screws to secure the KB2040 holder to the NeoKey mount.

Installing NeoKey PCBs

Flip the assembly over and position the two NeoKey PCBs so the mounting holes are lined up with the various mounting points on the 3D printed mount.

Ensure various wires are positioned away from any of the mounting holes.

Fasten & Secure NeoKey PCBs

While holding the NeoKey PCBs in place, insert and fasten the M3 x 6mm machine screws.

Reference the assembly photo to cross check where the 10x M3 screws are needed to be fastened.

Check Wiring

Flip the assembly over and double check the wires are not being obstructed and clear from any pinching or kinking.

Install Bottom

Orient the bottom half of the case with the NeoKey PCB assembly.

Insert the NeoKey PCB assembly into the bottom half of the case with the mounting holes lined up.

Secure PCB Mount to Bottom

Insert and fasten M3x8mm long machine screws to secure the NeoKey PCB mount to the bottom half of the enclosure.

Installing Switches to Key Plate

Get the 3D printed key plate and 48x mechanical key switches ready to install. Orient the key plate with the NeoKey PCB (the center tab faces away from KB2040's USB port).

Start by inserting switches on each corner of the key plate by snapping them into the plate. Make sure they're in the correct orientation (LED slots facing down).

Then, insert four more switches spaced apart like in the assembly photo.

Install Key Plate to NeoKey PCBs

Orient the key plate with the NeoKey PCBs and place it over the PCB.

Gently press down the various switches, ensuring the pins are fitting neatly into their respected sockets. 

Proceed with the switch installation by snapping switches into place, one by one, ensuring the pins are seating correctly into the key sockets.

Install Key Caps

Gather up your desired key caps to get ready to install them onto the mechanical key switches.

Pull up your key map to reference the placement of the key caps.

Firmly press the key caps onto the stems of the key switches to install them.

Installed Key Caps

Take a moment to review each key switch, making sure they match your key mapping.

If you find a key is misplaced, use a key puller to remove the key cap.

Install Top

Orient the top cover with bottom half of the case so the snap fit nubs match.

Firmly press the two parts together to snap fit them closed.

USB, Reset & Boot

Connect your keyboard to your computer using a data and power USB-C cable.

The bottom of the enclosure features button tabs for accessing the boot and reset buttons on the KB2040. The square shaped button is BOOT while the circular one is the RESET button.