Crap-Connect 2030

A DIY Tag-Connect adapter that doesn't drain your bank account. Some assembly required.

BOM

• 2x PCB (see tagconnect KiCad project folder)
• 6x pogo pins with ca. 1mm outer diameter, sufficiently thin tip
• 3x metal rods with ca. 1mm diameter used as alignment pins (e.g. long pin headers)
• 1x pin header 2x3, 2.54mm spacing
• Shrinkwrap

Assembly

1. Put the pogo pins into one of the PCBs. I've found a small hammer and some support on the oder side (X) to be useful; something like this:

         |  Hit here with hammer
         V
   
       | | |
       | | |
    ===========
    XX | | | XX
    XX | | | XX
    XX | | | XX
    XX | | | XX
    XX | | | XX  <- this side is the tips of the pogo pins
    XX       XX
   

2. Repeat for the second PCB:

         |  Hit here with hammer
         V
   
       | | |
       | | |
    ===========
       | | |
       | | |
    ===========
    XX | | | XX
    XX | | | XX  <- this side is the tips of the pogo pins
    XX       XX
    XX       XX
    XX       XX
    XX       XX
   

3. Make sure the tips of the pogo pins are able to move freely.

4. Solder the pogo pins into place. Make sure to not get solder in between the pins, it's close to impossible to get clean again.

5. Put the alignment pins (I) in their appropriate holes. Use the hammer if necessary. Should look something like this:

       | | |
     I | | | I
    ===========
     I | | | I
     I | | | I
    ===========
     I | | | I
     I | | | I   <- this side is the tips of the pogo pins
     I       I
   

6. Solder the alignment pins into place.

7. Solder the 2x3 pin header directly to the tail ends of the pogo pins. By now, the whole thing should look somewhat like this:

8. Wrap in shrinkwrak and you're done: