The start of a LONG Fuel repair thread...
#71
RE: The start of a LONG Fuel repair thread...
Yes, I installed the customer 1.0 CD that was posted and I also at that same time put in the updated version of the CD (at least that’s what I believed it was) from the SGI depot files section.

That’s what I ran.
weblacky
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11-21-2021, 11:55 AM
#72
RE: The start of a LONG Fuel repair thread...
Hi Weblacky,

FYI, here are the version reported by the online diags I have installed:

>> # ls
>> bridgeloc olenet olpci oltape olvst pandora
>> cached olmem olsio olusb onlinediag runalldiags
>>
>> # ./pandora -v
>> NOTE This diagnostic can NOT be run concurrent with any user jobs
>> CMDL ./pandora -v
>> TEST pandora System level stress test. Test(1/1), Loop(1/1)
>> REV Pandora version 5.1 built on Dec 11 2002 at 23:36:28
>> INFO Start time Mon Nov 22 09:52:11 2021
>> INFO Running on IRIX64 6.5.30m 07202013 IP35 (<HOST>)
>> EXIT Exiting...
>>
>> # ./olpci -v
>> REV Online PCI/PCI-X Bridge Config Space (OLPCI) version 2.3
>> REV built on Dec 11 2002 at 23:36:28
>> INFO Start time Mon Nov 22 09:52:58 2021
>> INFO Running on IRIX64 6.5.30m 07202013 IP35 (<HOST>)
>>
>> # ./olenet -v
>> REV olenet version 2.0pre12 built on Dec 11 2002 at 23:36:28
>> INFO Start time Mon Nov 22 09:53:34 2021
>> INFO Running on IRIX64 6.5.30m 07202013 IP35 (<HOST>)
>>
>> # ./oltape -v
>> REV Online Tape Test (OLTAPE) version 2.0 built on Dec 11 2002
>> REV at 23:36:15
>> INFO Start time Mon Nov 22 09:54:03 2021
>> INFO Running on IRIX64 6.5.30m 07202013 IP35 (<HOST>)
>>
>> # ./olvst -v
>> REV Online Socket-Based Network Test (OLVST) version 2.0 built
>> REV on Dec 11 2002 at 23:36:15
>> INFO Start time Mon Nov 22 09:54:22 2021
>> INFO Running on IRIX64 6.5.30m 07202013 IP35 (<HOST>)
>>
>> # ./olmem -v
>> REV olmem version 1.4 built on Dec 11 2002 at 23:36:28
>> INFO Start time Mon Nov 22 09:54:33 2021
>> INFO Running on IRIX64 6.5.30m 07202013 IP35 (<HOST>)
>> INFO
>> INFO NOTE: Most memory errors are seen by the kernel instead of
>> INFO olmem. Check the console and /var/adm/SYSLOG for memory
>> INFO errors after olmem is done.
>> INFO
>>
>> # ./olsio -v
>> REV Online SIO Port Test (OLSIO) version 3.1 built on Dec 11
>> REV 2002 at 23:36:28
>> INFO Start time Mon Nov 22 09:54:44 2021
>> INFO Running on IRIX64 6.5.30m 07202013 IP35 (<HOST>)
>>
>> # ./olusb -v
>> REV olusb version 1.1.2 built on Dec 11 2002 at 23:36:15
>> INFO Start time Mon Nov 22 09:55:02 2021
>> INFO Running on IRIX64 6.5.30m 07202013 IP35 (<HOST>)
>>
>> # ./bridgeloc -v
>> Mon Nov 22 09:55:45 AEDT 2021
>> IRIX64 <HOST> 6.5 6.5.30m 07202013 IP35
>> REV Online PCI/PCI-X Bridge Locator & Diag Listing Utility 2.0
>>
>> INFO PCI bridges were found at the following locations:
>>
>> BRDG /hw/module/001c01/Ibrick/xtalk/14/pci
>> BRDG /hw/module/001c01/Ibrick/xtalk/15/pci
>>
>> INFO PCI-X bridges were found at the following locations:
>>
>>
>> INFO Devices located at the following /hw locations may be
>> INFO tested using the indicated online diagnostic:
>> INFO (The format of each line is a device code followed by a
>> INFO partial command line for the applicable online diagnostic.
>> INFO Additional command line options may be required to
>> INFO properly test the device. Please refer to the man page
>> INFO for the particular diagnostic for details. Device
>> INFO codes are BRDG for PCI/PCI-X Bridges, ENET for ethernet
>> INFO interfaces, SIO for serial ports, USB for the USB and
>> INFO RTI for Real-Time Interrupts.)
>>
>> BRDG olpci -v /hw/module/001c01/Ibrick/xtalk/14/pci
>> BRDG olpci -v /hw/module/001c01/Ibrick/xtalk/15/pci
>> ENET olenet -v /hw/module/001c01/Ibrick/xtalk/14/pci/1
>> ENET olenet -v /hw/module/001c01/Ibrick/xtalk/15/pci/4
>> SIO olsio -v /hw/module/001c01/Ibrick/xtalk/15/pci/4
>> USB olusb -v /hw/module/001c01/Ibrick/xtalk/15/pci/5
>>
>>

Cheers from Oz,

jwhat/John.
jwhat
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11-21-2021, 11:16 PM
#73
RE: The start of a LONG Fuel repair thread...
Okay, I got parts today so I was able to replace the HDD bay fan header on my Fuel mainboard.  So originally the locking tab was hanging by a thread, then it broke when I was plugging/unplugging all the time. It would have been fine, but it wasn't solidly attached and COULD slip off with minor effort and without the tab you COULD install the connector backwards!  Not good.  So I just decided to chance an issue and replace it.

I could not find the EXACT header used, so I went off what was the plug attached to the HDD fan, I found the datasheet but didn't find the connector part number.  So I just went with the molex KK series locking headers as they are the most common 2.54mm vertical locking fan-header used. 

Header used was a Molex 0022232031.

I increased the temp on my desoldering gun to closer to 750F, expecting a huge fight with a board this thick.  But that didn't happen, it ended up going extremely fast to remove, I added a small amount of leaded solder to the fan header joints, heated them with the gun, wiggled, engauged suction, wiggled again, and remove gun while under suction...clean holes...all three times...zero issues on removal.  The header literally fell out with a slight push.

   

The only issue I had (slight issue) is that it's basically all metal, I cannot hold the part with my fingers and tack it and I didn't realize how much extra room the vias had in them.  

   

So while soldering went fine, I used some hemostats to hold it through the board which resulted in it being slightly crooked, I wish I could have done something about it, but you're working with the part held by the underside, you cannot ensure alignment very easily without also risking constantly handling the board or burning yourself trying to hold it in alignment.

   

So fan header is installed, but little out of alignment...oh well it's not a very visible part/issue and low touch and correct attachment is more important and it new and safe now.

   

So another thing done...however I'm not going to put it back together, I've decided I don't enjoy constantly disassembling this Fuel, so I'm going to tackle the bottom metal (kind of did today) by removing the rivets and going at the bottom and side panels.  I only get one shot, I don't want to keep fiddling, so if I ca make an improvement...fine..I just need this to end so I can move on to another SGI system...getting bored doing these constant, small, items.

Molex / 0022232031
(This post was last modified: 11-27-2021, 03:13 AM by weblacky. Edit Reason: Pics )
weblacky
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11-27-2021, 03:12 AM
#74
RE: The start of a LONG Fuel repair thread...
Okay, so today I drilled out the 3 rivets in the lower front and slide out the bottom panel.  Actually that ended up being very easy!  I've already riveted it back together as well.

   

   

I used various things to try to get things looking better.  They will never be perfect (of course) but I got it much improved and I hope it will at least sit flat without wobbling now.  I also pulled the bend out around the bottom panel (video card display output area) out and I think I was able to pop it out pretty well.

   

Here's the pics I took (trying to keep within the posted limit).

Case is back together but I have not placed anything back inside yet.  I'll do that later after I've had a chance to reexamine the other CPU PIMM with my working CPU PIMM.


Attached Files Image(s)
                           
weblacky
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12-02-2021, 12:43 AM
#75
RE: The start of a LONG Fuel repair thread...
Okay...the Fuel is back together with it's repaired fan header on Mainboard, new V10 graphics, existing PIMM, full 2GB of RAM, and original 18.2 HDD.  She all runs right into Irix, no issues detected  
Joy

I do still need to fix the fuel door latch that's broken off but that's underway right now, so I may post about that...or use another thread for that info.

Code:
SGI SN1 L1 Controller

Firmware Image B: Rev. 1.48.1, Built 01/22/2007 11:34:20

001a01-L1>env

Environmental monitoring is enabled and running.



Description    State       Warning Limits     Fault Limits       Current

-------------- ----------  -----------------  -----------------  -------

           12V   Wait Pwr  10%  10.80/ 13.20  20%   9.60/ 14.40    0.188

        12V IO   Wait Pwr  10%  10.80/ 13.20  20%   9.60/ 14.40    0.188

            5V   Wait Pwr  10%   4.50/  5.50  20%   4.00/  6.00    0.104

          3.3V   Wait Pwr  10%   2.97/  3.63  20%   2.64/  3.96    0.688

          2.5V   Wait Pwr  10%   2.25/  2.75  20%   2.00/  3.00    0.000

          1.5V   Wait Pwr  10%   1.35/  1.65  20%   1.20/  1.80    0.000

        5V AUX   Wait Pwr  10%   4.50/  5.50  20%   4.00/  6.00    5.044

      3.3V AUX   Wait Pwr  10%   2.97/  3.63  20%   2.64/  3.96    3.302

PIMM 12V BIAS   Wait Pwr  10%  10.80/ 13.20  20%   9.60/ 14.40    0.188

          SRAM   Wait Pwr  10%   2.25/  2.75  20%   2.00/  3.00    0.221

          VCPU   Wait Pwr  10%   1.13/  1.38  20%   1.00/  1.50    0.014

     PIMM 1.5V   Wait Pwr  10%   1.35/  1.65  20%   1.20/  1.80    0.000

PIMM 3.3V AUX   Wait Pwr  10%   2.97/  3.63  20%   2.64/  3.96    3.285

   PIMM 5V AUX   Wait Pwr  10%   4.50/  5.50  20%   4.00/  6.00    5.018

  XIO 12V BIAS   Wait Pwr  10%  10.80/ 13.20  20%   9.60/ 14.40    0.188

        XIO 5V   Wait Pwr  10%   4.50/  5.50  20%   4.00/  6.00    0.104

      XIO 2.5V   Wait Pwr  10%   2.25/  2.75  20%   2.00/  3.00    0.000

  XIO 3.3V AUX   Wait Pwr  10%   2.97/  3.63  20%   2.64/  3.96    3.302



Description     State       Warning RPM  Current RPM

--------------- ----------  -----------  -----------

FAN  0  EXHAUST   Wait Pwr          920            0

FAN  1       HD   Wait Pwr         1560            0

FAN  2      PCI   Wait Pwr         1120            0

FAN  3    XIO 1   Wait Pwr         1600            0

FAN  4    XIO 2   Wait Pwr         1600            0

FAN  5       PS   Wait Pwr         1349            0



                              Advisory   Critical   Fault      Current     

Description       State       Temp       Temp       Temp       Temp      

----------------- ----------  ---------  ---------  ---------  --------- 

0 NODE 0           Wait Pwr    [Autofan Control]    80C/176F   12C/ 53F

1 NODE 1           Wait Pwr    [Autofan Control]    80C/176F   12C/ 53F

2 NODE 2           Wait Pwr    [Autofan Control]    80C/176F   12C/ 53F

3 PIMM             Wait Pwr    [Autofan Control]    80C/176F   12C/ 53F

4 ODYSSEY          Wait Pwr    [Autofan Control]    80C/176F   12C/ 53F

5 BEDROCK          Wait Pwr  Not currently available



001a01-L1>INFO: 001a01 will power up system in  5 seconds...

INFO: 001a01 powering up the system.


entering console mode  001a01 CPU0, <CTRL_T> to escape to L1
Starting PROM Boot process 


IP35 PROM SGI Version 6.210  built 02:33:51 PM Aug 26, 2004
Running in DDR mode
Testing/Initializing memory ...............        DONE
Copying PROM code to memory ...............        DONE
Discovering local IO ......................        DONE
Discovering NUMAlink connectivity .........        
Local hub NUMAlink is down.
*** Local network link down
DONE
Found 1 objects (1 hubs, 0 routers) in 5900 usec
Waiting for peers to complete discovery....        DONE
No other nodes present; becoming global master
Global master is /hw/rack/001/bay/01
\\\\Intializing any CPUless nodes..............        \\DONE
\Checking partitioning information .........        DONE
No other nodes present; becoming partition master
\Loading BASEIO prom .......................        DONE

BASEIO PROM Monitor SGI Version 6.210  built 02:30:38 PM Aug 26, 2004 (BE64)
1 CPUs on 1 nodes found.
Automatic update of PROM environment disabled

PS/2 Keyboard & Mouse diagnostics
    Found mouse on port 0
    Found keyboard on port 1
PS/2 Keyboard & Mouse diagnostics passed

Graphics diagnostics

Odyssey board #0 found on nasid 0
Running Odyssey xtalk sanity diag...
        Board version 1 - Buzz revision 2B
        On board sdram size: 32 Mb
        Cas latency: CAS 3
        2 banks by sdram module
Running Odyssey Buzz registers diag...
Device passed diagnostics

Installing PROM Device drivers ............            
Base I/O Ethernet set to /dev/ethernet/ef0
Installing Graphics Console...
graphics install: searching for pipe 0

Walking SCSI Adapter 0, (pci id 1)
1+ Device Vendor Product: QUANTUM ATLAS10K2-TY184L
2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13- 14- 15- = 1 device(s)


Walking SCSI Adapter 1, (pci id 1)
1- 2- 3- 4- 5- 6+ Device Vendor Product: TOSHIBA DVD-ROM SD-M1711
7- 8- 9- 10- 11- 12- 13- 14- 15- = 1 device(s)

Initializing PROM Device drivers ..........             DONE


escaping to L1 system controller

001a01-L1>l1

L1 command processor engaged, <CTRL-D> to exit.

001a01-L1>env

Environmental monitoring is enabled and running.



Description    State       Warning Limits     Fault Limits       Current

-------------- ----------  -----------------  -----------------  -------

           12V    Enabled  10%  10.80/ 13.20  20%   9.60/ 14.40   11.938

        12V IO    Enabled  10%  10.80/ 13.20  20%   9.60/ 14.40   12.063

            5V    Enabled  10%   4.50/  5.50  20%   4.00/  6.00    5.070

          3.3V    Enabled  10%   2.97/  3.63  20%   2.64/  3.96    3.354

          2.5V    Enabled  10%   2.25/  2.75  20%   2.00/  3.00    2.470

          1.5V    Enabled  10%   1.35/  1.65  20%   1.20/  1.80    1.466

        5V AUX    Enabled  10%   4.50/  5.50  20%   4.00/  6.00    5.018

      3.3V AUX    Enabled  10%   2.97/  3.63  20%   2.64/  3.96    3.302

PIMM 12V BIAS    Enabled  10%  10.80/ 13.20  20%   9.60/ 14.40   12.000

          SRAM    Enabled  10%   2.25/  2.75  20%   2.00/  3.00    2.509

          VCPU    Enabled  10%   1.13/  1.38  20%   1.00/  1.50    1.255

     PIMM 1.5V    Enabled  10%   1.35/  1.65  20%   1.20/  1.80    1.495

PIMM 3.3V AUX    Enabled  10%   2.97/  3.63  20%   2.64/  3.96    3.285

   PIMM 5V AUX    Enabled  10%   4.50/  5.50  20%   4.00/  6.00    5.018

  XIO 12V BIAS    Enabled  10%  10.80/ 13.20  20%   9.60/ 14.40   11.875

        XIO 5V    Enabled  10%   4.50/  5.50  20%   4.00/  6.00    5.070

      XIO 2.5V    Enabled  10%   2.25/  2.75  20%   2.00/  3.00    2.470

  XIO 3.3V AUX    Enabled  10%   2.97/  3.63  20%   2.64/  3.96    3.302



Description     State       Warning RPM  Current RPM

--------------- ----------  -----------  -----------

FAN  0  EXHAUST    Enabled          920         1180

FAN  1       HD    Enabled         1560         2149

FAN  2      PCI    Enabled         1120         1534

FAN  3    XIO 1    Enabled         1600         2163

FAN  4    XIO 2    Enabled         1600         2020

FAN  5       PS    Enabled         1349         2122



                              Advisory   Critical   Fault      Current     

Description       State       Temp       Temp       Temp       Temp      

----------------- ----------  ---------  ---------  ---------  --------- 

0 NODE 0            Enabled    [Autofan Control]    80C/176F   16C/ 60F

1 NODE 1            Enabled    [Autofan Control]    80C/176F   14C/ 57F

2 NODE 2            Enabled    [Autofan Control]    80C/176F   12C/ 53F

3 PIMM              Enabled    [Autofan Control]    80C/176F   20C/ 68F

4 ODYSSEY           Enabled    [Autofan Control]    80C/176F   13C/ 55F

5 BEDROCK           Enabled    [Autofan Control]    85C/185F   16C/ 60F



001a01-L1>


001a01-L1>pwr

Supply          State Voltage    Margin  Value

--------------  ----- ---------  ------- -----

           12V     on   11.938V      N/A

        12V IO     NC   12.000V      N/A

            5V     NC    5.070V      N/A

          3.3V     NC    3.354V   normal     0

          2.5V     on    2.470V   normal     0

          1.5V     NC    1.466V   normal     0

        5V AUX     NC    5.018V      N/A

      3.3V AUX     NC    3.285V      N/A

PIMM 12V BIAS     NC   12.000V      N/A

          SRAM     NC    2.509V   normal     0

          VCPU     on    1.255V   normal   117

     PIMM 1.5V     NC    1.495V   normal     0

PIMM 3.3V AUX     NC    3.285V      N/A

   PIMM 5V AUX     NC    4.992V      N/A

  XIO 12V BIAS     NC   11.875V      N/A

        XIO 5V     NC    5.070V      N/A

      XIO 2.5V     on    2.470V   normal     0

  XIO 3.3V AUX     NC    3.302V      N/A

001a01-L1>

001a01 ATTN: Power Down: issue 'pwr d' again to immediately power down.


So she's fixed!

Now when I bent back the case metal it made it harder to insert my V10 card...cannot even easily get it out anymore...not sure why...so I'll likely wait until I'm doing my Tezro and re-test my original V10 card...I know sucks waiting...but whatever...I'm happy and maybe the card works...maybe not.  I've not touched the original PSU as I plan to get to Fuel PSU after I finish with Tezro and get through Octane...so it's on the waiting list!  Right now I'm using a Fuel ATX Adapter and 700W FSP PSU.


I may add to this thread, but I'll consider this completed as the system has no more issues, appears fully functional, boots all the way to graphics, what more did I expect?


So I'll summarize the issues for those that don't want to read the entire posting.

System arrived with heavy dents, advertised as DEAD by the seller.

System had a shorted graphics card with a shorted DS1780 IC (ENV monitoring)  Attempted to fix the card by installing a NEW DS1780 IC and got ENV monitoring back online but there was an additional short on the 12V XIO Bias and I ending up buying a new V10 card...but I didn't know it wasn't booting for other reasons after ENV was fixed! So I put a used V10 in it...nothing changed...kept the new V10 from that point on.

I couldn't get to the main console (I thought the L1 was stopping me with a error message that said "pre-power check failed"). Turns out that some Fuels have Serial 1 output their console with the internal header outputing L1.  Once I found that out I plugged into both serial ports and got the output.  I found that I was dumping to POD due to "invalid NVRAM DATA", I'd never gotten this output before so had I seen this I might have held off buying the graphics card, but oh well.

This error clearly means my SNAPHAT battery was dead, I order the bigger snaphat and plugged it in, re-inited.  Now the system would actually get farther and also the console and the L1 were now on the same internal header port!

But then I saw a register error and a memory initialization error.

The original owner had obviously seen this issue because they used a DIMM layout that couldn't have been legal...but worked due to the fact that DIMM3 memory sizing wasn't working.  The original DIMMs were 256MB, 256MB, 512MB, 256MB.  

This worked because the PROM assumed DIMM3 was 256MB and made an error about it...didn't matter what module, of any size, you inserted.  So I removed the mainboard and cleaned the legs of all the ICs under it, and inserted 4 x 512MB of DIMMs I already owned from my Tezro (prior to memory upgrade years ago). When it booted it instantly complained about DIMM1 being gone and stopped.  This wasn't good, so I reinstalled the same DIMMs again and this time got BACK everything but DIMM3 being fully recognized.  I then decided to reinstall and wiggle and push the DIMMs to cause the contacts some scratching movement (I do this on PCs as well to confirm seating).  After that...ALL MEMORY TESTS PASSED!  All 2GB seen...I won't be upgrading to more (why bother?) so I'm happy.

The HDD bay fan header on the mainboard was loose and not locking when I got it, the lock tab soon fell off.  I ordered a common molex KK series 3 post 2.54mm locking header and desoldered the old one and soldered the new one in.  

I've now reassembled everything and booted.  I also upgraded the L1 firmware to version 1.48 (last patched version).

So that along with those items, the HDD wasn't jumpered for ID correctly (conflicted with mainboard ID) and the optical drive was not placed correctly the last connector on the ribbon (causing some SCSI noise).

Original SCSI SGI HDD worked fine, loaded irix 6.5.30 via optical drive (I have official media for that version).

So those were the many problems.  She's running well now and I'm going to try to shine her up and put her up with the other systems and move on!

Thanks to everyone who participated and gave their thoughts.  I'll start more threads as I go with repairs.

Fuel

Remember to have fun!
(This post was last modified: 12-07-2021, 04:52 AM by weblacky. Edit Reason: Fuel door latch not mentioned. )
weblacky
I play an SGI Doctor, on daytime TV.

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12-07-2021, 04:47 AM
#76
RE: The start of a LONG Fuel repair thread...
Amazing stuff dude! I appreciate this thread and will start a subforum sooner or later for immortalizing these threads that are truly... Epic.Not all of this can be put into a wiki article after all.

I'm the system admin of this site. Private security technician, licensed locksmith, hack of a c developer and vintage computer enthusiast. 

https://contrib.irixnet.org/raion/ -- contributions and pieces that I'm working on currently. 

https://codeberg.org/SolusRaion -- Code repos I control

Technical problems should be sent my way.
Raion
Chief IRIX Officer

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12-07-2021, 06:49 AM
#77
RE: The start of a LONG Fuel repair thread...
Hi Weblacky,

echoing Raion, "Amazing stuff ..." indeed.

This is most comprehensive drill down into fixing Fuel HW I have seen.

Really helpful to all current and future Fuel owners.

Thanks very much.

Cheers from Oz,

jwhat/John.
jwhat
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12-07-2021, 07:40 AM
#78
RE: The start of a LONG Fuel repair thread...
Nice work!
jan-jaap
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12-07-2021, 02:46 PM
#79
RE: The start of a LONG Fuel repair thread...
Yes, Indeed nice work, my Fuel is still humming along, but sure that one day it will need some work. Very interested to see how you go about fixing the latch on the door, mine is broken as well, I am sure just about everyone else's is as well. 3D print the part and glue it on?
indigofan
Tezro

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12-07-2021, 04:34 PM
#80
RE: The start of a LONG Fuel repair thread...
(12-07-2021, 04:34 PM)indigofan Wrote:  Yes, Indeed nice work, my Fuel is still humming along, but sure that one day it will need some work. Very interested to see how you go about fixing the latch on the door, mine is broken as well, I am sure just about everyone else's is as well. 3D print the part and glue it on?

I have a couple different ideas, but it needs to work the first time.  One issue is the proper "throw" distance for the clip, the other is the attachment method, and the third is the amount of material on the original clip that may need to be cut/removed to allow the 3D print on it?  I have the front face off right now, so I'll try to actually see from behind how it fits (I want a tight door) since the print is a known length, I just have to find the proper offset, then that offset should hold true for everyone!  Likely, I'll be using a binary 5min epoxy to do the attachment, else a very tiny tapping screw in a pre-drilled hole.



Thanks everyone for the recognition, I had fun but also...I had to do it...so why not share?  I really love hearing about fixing and repairs. After I clear my work space, I'll be tackling my old, sick, Tezro,  I'll be doing it's PSU rebuild as well.  She hasn't been safely started for 9 years!  I also got upgrades for it too.  Plus I still need to try to solve the whole 1.8v env low voltage issue!  So look forward to that when I get started!  I already believe the I have the right SMD caps for the 1.8V VRM area (should it need it) and the parts for two more Tezro PSU rebuilds.  So the only thing stopping me is my attitude/time/effort!

Stay Tuned!
weblacky
I play an SGI Doctor, on daytime TV.

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12-07-2021, 04:56 PM


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