SMD Repair - Easy to Complex - Baltimore Amateur Radio ClubBaltimore Amateur Radio Club

TIPS: Rig models can be researched online for the common problems and solutions.

MODS: can be done to open bands. The cost is LABOR and the know-how. A real shop has to charge a diagnostic fee, Min labor of $125 for repair. Add shipping back and forth. A minimum can be $200 or can be $600 to recap a complete rig from 1990 to 2000. Capacitors are the issue, end of life, and leaking. Hours on and care, and a higher serial number are things to look for.

Labor Rates: All labor rates will continue to climb. Radio rates are $125 and hour.

Example: a board for display. 3 radial caps “top quality”, Reflow some joints and repair traces. https://w3ft.com/wp-content/uploads/2026/03/displayboardrepair850kw.pdf/

LEAD – Danger and Risk – Ventilate, wash hands

Be LEAD Aware. Some boards have solder with lead. Sometimes we add leaded solder to make removal easier.

Eye Protection. Fumes need to be vented, and washing hands after is key for safety. Do not eat, smoke, or vape while soldering. Wipe down the table surface after completion.

I worked at a firearm range for 25 years. Blood lead levels never had an issue. Precautions are simple.

Key Safety Measures for Handling Lead Solder

Ventilation: Always work in a well-ventilated area to reduce exposure to fumes. Using a fume extractor to direct fumes away from your face is recommended.
Personal Protective Equipment (PPE): Wear safety glasses or face shields to protect from splashing metal. Use gloves when handling solder to avoid skin contact.
Hygiene Practices: Never eat, drink, or smoke in the soldering area. Wash your hands and face thoroughly with soap and water after handling solder, especially before eating or leaving the workspace.
Work Area Contamination: Keep the work area clean and use dedicated materials to avoid bringing lead dust into living spaces.
Clothing: If doing heavy soldering, consider wearing designated work clothes and changing them before going home to avoid taking lead dust to family members.
Alternative Materials: Lead-Free Solder.

Self-Training & Tools

Solution: learn a skill, and the cost is under $100. If you can borrow a setup, even better. 10 hours of learning ( 5 hrs video, 5 hrs hands-on with old boards). At 20 hours, a novice. be able to check a component and replace caps of all types. Through hole, SMD, or ceramic. Be able to do minor trace repair.

Most basic tools are soldering irons with multiple tips that vary in temperature from 300 to 800 degrees. Solder wick, pick and tweezers tool,s and a hot air rework station.

My station for repair and first training. https://youtu.be/UGDFQsCc0Rg?si=71eDl7ROmCxtcM47 $100 to learn and have the gear needed.

Training is progressive, using old computer boards to practice on.

Learn how much heat to use when using liquid flux and solder paste. How not to burn yourself.

Day 2 MISTAKES !!!! Training https://youtu.be/9HYxRRFrIns?si=YkndfEGlYsT5Kwhr, making mistakes

Day 3 CHIP 144 pin IC

Day 4 – Trace repair – When traces get eaten away by electrolyte, cut, or pulled out. Scrape off the outer cover to show copper. Using 43 AWG wire bridge over the missing trace. solder and continuity test. UV Resin curing. Need to redo with 43 AWG wire.

Day 5 VIAS: Best described as a connection between the PCB layers. Electrolyte gets in and eats the copper. Have to clean, rebuild with wire, and solder.

Above – leaky cap took out 3 traces. Not the best looking, but the continuity checks out. Replacing with Panasonic 470 μF 25V. The original was 16v. 2 others to replace 100uf 25 v.

$3.00 in parts to fix.

I use Panasonic caps. Some I have to order, most are on Amazon. I try to go up in volts to help the new caps last. This board, Caps all were 16 Volts, replacing with 25 volts.

Final Project: a 7$ Board with 120 components to install. If done correctly will build an LED light display.