Picture of PCB Binder
So you like to take stuff apart and salvage stuff?! What do you do with those PCB boards after you take stuff off of them?

Well i made a Binder... its quite heavier than a regular binder, but its also stronger and looks kind of cool.

For this project i used the following materials

Wire Cutters
a Knife *
soldering iron
screw driver
a "dremel tool"
a paintbrush (mainly for cleanup or dust-off work)

PCB boards **
a Regular cheap Binder (if its used even better, free stuff rocks!... make sure it still works tho)
2 Screws with their nuts (around 0.5" long)
Contact cement ***
a sheet of foam ***
a bunch of jump rings (small rings used mainly to make Charm Bracelets)

*necessary to cut foam and pry stuff off your PCB, anything that does this job will do
** as big as you can get em, for this project you will need at least 2 sheets (11.5 " x 10.25") and 1 (11.5" x 1") minimum
*** Optional but you may decide to use Them in the end (it protects the back of your notes and also gives a padded support)

I have been asked where did i get those huge PCB's here is my response: (if you know the name or kind of the equipment im talking about please comment, so others know where to look :)

Well im not sure what it was, there were 2 huge metallic boxes (the kind you put on a rack thing) On the front one reads " COGNEX 2000 vision systems" the other one reads "Turbo HR+ ESI vision products" on the back both have around 4 camera outputs and the second one also has some serial ports marked "SIO"
i found this picture of one of the PCB sources
Box 1

i assumed they were some part of a closed circuit "surveillance system"... basically when they throw away stuff at the electronics department @ school they let us take what we want XD

UPDATE!!! googfan said he found some Server PCB's that are quite large, hope it helps

SAFETY FIRST! please! when using a cutting tool, or when you are prying things off your board wear eye protection, and cover your nose, i don't think PCB "sawdust" or solder fumes are good for your health, also i had a few close calls before i decided i HAD TO use the glasses
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Step 1: Design

Picture of Design
Binder outside.JPG
This step is important if you want the end result to look cool.

First of all measure your Old/Cheap Binder, you will need to know the size of each panel (from now on i will call them Front, Side and Back panel) as well as the placement of the "clamp" (thanx to technodude92) when i say placement i mean to check the location of the bolts that hold it to the back panel or side panel (depending on the binder you want to make)

i wanted to make it bigger

cheap/free old binder
front and back: 11.5" X 10.25"
side: 11.5" X 1.5"

My Binder:
front and back 12.5" X 10.5"
Side 12.5" X 1 5/8"

while you are measuring consider how the board looks, is there a component that stands out?, would it look better as a side panel or front panel? if i cut it this way this component has to be desoldered or cut in half?... be creative

Step 2: Desolder the backside PCB

Picture of Desolder the backside PCB
Bunchofpins aft.JPG
Now that you have an idea of what you want the binder to look like its time to get to the hard part

there are some nice instructables on desoldering complicated stuff

Tool Tip: How to Salvage PCB Parts by 1up
Salvage surface mount components by neelandan
Heatgun Desoldering by Mage2
Where's my desoldering iron!? by whatup.dub

Also a tip by Ductape667 was to set the entire PCB on an electric skillet and then plucking off all the components of the PCB

for all you scavengers this should be easy, for the rest of us, when patience runs out use the dremmel tool but use it wisely, cut the leads as far from the board as possible so you can desolder them separately (usually the hardest stuff to desolder is "multi-pinned" stuff

You need to desolder the back panel... because it needs to be flat on that side so you can lay it on your desk and also, those leads can damage your notes or hands if you are not careful (however thats also what the foam and contact cement is used for, you can cover the leads with a sheet of foam)

for me this was the hardest part because im not to patient and this takes quite some time to desolder with a 25w soldering iron and some pliers., to get each lead out i used the tip of the iron and a knife to pick each lead out of the board as you desolder it in just one move (use the tip and the knife as "chopsticks"... -.- using both hands)

Step 3: Cutting

Picture of Cutting
troubl cutting 2.JPG
cutting aft clnup.JPG
You guys done!? Hard part is over, time to get your safety gear (if you haven't already) its a must for this step!

By now you have the measurements for your binder, so its time to draw some lines in the PCB with a marker or something (i used a cd marker and later removed the ink with alcohol)

get your "dremel" tool and very carefully (and using your glasses... don't forget) cut along the lines you just drafted, BE CAREFUL.

you can use a paintbrush to clean the panels afterwards.

Step 4: Panel Assembly

Picture of Panel Assembly
also binder holes.JPG
in order to link all the panels together i used some jump rings and my drill,

my front panel had some space between the edge of the board and the components on one side so i did the holes to link the panels there, on the back i had to place the ring holes wherever an empty space matched on both panels

Again, use your measuring tape, or ruler or whatever to make marks where you want to place the rings, make sure that they match up with marks on the other panel, and that they are a bit closer to the edge of the board than half the inner diameter of the ring

*CAUTION weird mechanical explanation*
Thats because you want to be able to open the binder with panels at a 180º angle and when you do that, the ring must be centered, but it has to have some slack to move freely so you need to give it a "hole to hole" distance of "less than the inner diameter" and the distance from the outer edge of the holes has to be bigger than the outer diameter.

This is as long as the distance from the edge of the panel to the hole isn't smaller than the thickness of the panel in which case i would recommend using larger rings

At first i made the holes the exact diameter of the rings, big mistake, the rings get stuck and bend/break/etc... overall a bad idea.

check the images to see what finally worked.

Once you are done making the holes its time to get your pliers and put those rings through each pair of matching holes. i also used some solder to hold the ends of the rings together, that way it looks much better

Step 5: Set the "Clamp"

Picture of Set the
binder closeup screw back.JPG
i don't know how this thing is called... sorry

anyway, this is what makes the binder.

its time to measure (if you haven't already) the distance between the bolts in the clamp and the offset distance from the inner edge of the original binder, i've seen it mounted on the side panel as well as the back panel, i mounted it on the back panel

the hard part is removing the bolts from the old binder, i tried to drill the top (or bottom i dunno) of the bolt as you do with rivets, the problem is that the bolt spins with the bit and anyway when you are done and try prying the clamp off your old binder it bends very easily WHICH IS NOT GOOD, the system used to pop the rings open and shut is really simple but bending this piece is its worst enemy

So anyway what i ended up doing was using the dremmel tool on the back side of the binder, and cut off the head of the bolts, removal was so easy after that

Now get your Drill bits and find one that matches the screws you got for this job.

the procedure is pretty easy overall just make your markings carefully so it doesn't look crooked in the end

Once you tighten the nuts on the back side you can put a dab of nail glue (the kind women use to put fake nails on, not the kind used on carpentry) or a similar glue so that it gets on the threads of the nut and locks it into place

Step 6: Finishing up

Picture of Finishing up
finished inside.JPG
now that you have the basic binder finished...

The inside of the back panel is not much of a working surface... YET, thats why i bought some sheets of foam.

This step is real simple: Measure twice Cut once... when measuring just take into account the type of paper you will be using

I used the kind of glue shown in the picture... one word of advice; when you apply the glue to the foam, the foam starts to like expand and stuff so it will look crooked if you glue it that way. (i know mine did)

so i ended up having to reshape it with an Xacto knife once i glued it, if i were you id try to apply some glue on the PCB and then lay the foam on top of it.

i added another sheet of foam on the front as if it were a regular binder sheet only a bit bigger

And its done!!!

This is my very first instructable so all comments that could help me make this one a better instructable are very welcome, also i am not a native english speaker so i don't know some Vocabulary related to tools and stuff like that, id also appreciate any help with that

WOW front page popular instructable... im happy :) !!!
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Win7Maniac5 years ago
 Holy crap, what's that front panel from!?!? Even a mobo doesn't have that many IC's!! I gotta get myself one of those!

Awesome project, great idea. I love it.
Your little yellow BATTRAY would LEAK soon or later.... and damage your other stuff, papers, boards ....u should take it off, this one.
killrsheep (author)  alex7street475 years ago
i really dont know the internal structure of Lithium Batteries but, they are not electrlolitic are they????, i dont think it would have leaked... and as i said before, that battery sadly fell off and got lost, it looked pretty nice tho so even if i still had it and it leaked i'd probably just seal it off with some sort of resin
seal it off by resin-paint, maybe it ok. dont forget to seal the tiny trought-hole also....but these rust could crowl bellow green-resin of copperline. ive seen it before, just check your oldy abandoned board if u wanna be sure of. M/B manufacture might aware of it, and replace it with button Batteries. ;otherwise use button Batteries as replacement. u could add a flip-flop activated by a switch, it would glow when the book being token from it places or being opened... if u good on microcontroller like atmega128 + tiny wires + smd stuff(took it from your abandon boards), u could do more with it... ;) Lot of Love dude. u are creative. i like your idea.
killrsheep (author)  alex7street475 years ago
thanks, it means a lot, im glad so many people liked it :)
Shane11636 years ago
lol that looks cool! I had a bunch of old server boards but then I ripped out some of the ICs and sold the boards to the scrap yard!
grenadier6 years ago
I came across 3 server pcbs that are twice as big as what he's got.
killrsheep (author)  grenadier6 years ago
Great i think I'll update the instructable to include that, so many ppl are asking about it XD
juse6 years ago
Commercial PCB shops use strychnine during the fabrication process, so BE CAREFUL !!! Wash those hands. Also, FR4 is the most common material and it is fiberglass, so the dust from it will mess you up as well. Personally I would stay away from cutting up PCBs. It's not worth it for something that will probably be tossed in a few years anyway.
munchman6 years ago
I love this. I just need to find some big PCB's
use computer motherboards. they work well
no they dont, they are smaller than a4
look at my pics
wyzm45ter6 years ago
awesome dude. if I made one of these I'd be the king of my class. great instructable
killrsheep (author)  wyzm45ter6 years ago
finding PCB's that size seems to be the hardest part, if you do find em go ahead and make one, they are pretty resistant, and yeah its a nice piece of conversation
I made one out of 3 computer mother boards.
killrsheep (author)  devicemodder6 years ago
cool!!!! would it be possible for you to post some pics of it? Thanks
It would be cool if you would add LEDs and a small battery , it so it looks like the circuit-board is still "alive"
I decided to do something like that for my digital electronics class. I will use a couple of old computer motherboards, some LED's, and a cold cathode tube as well. Im really into this kind of stuff and its really funny to see the other kids reactions to flashing objects. I was also thinking of wiring a small pair of speakers that I could hook my MP3 player up to.....
killrsheep (author)  zupperzipper6 years ago
it already has... um had those, the yellow thing WAS a lithium battery (wich fell of and got lost) and there are some led's (a row of 4) on it, perfect for a 4bit binary clock, but i have been procrastinating around that idea, sorreh
Notbob6 years ago
I once made a small note pad-ish book with a cover like this. Even after stripping off the majority of the things that would catch on other thing, I still find it catching on thing stuff. Any suggestions on how i could fix this, As I don't want to remove everything from the board.
killrsheep (author)  Notbob6 years ago
well first if the stuff catching onto other stuff is lead residue you could reheat and try to get it as smooth as possible, but thats probably not the problem , and sanding it is also a bad idea cuz it would mess up the design .... what ___Phi__ said sounds good, im actually right now finding a solution for the back of the front cover since i want to fold the binder and rest it on the table to write directly on it that way too ... i was going to place a green sheet of foam as i did with the back but i migh use some sort of resin.... if/when i do i will update the instructable
It's probably also a bad idea to sand it, because if it is lead residue, you'd be breathing fun lead fumes into your lungs.
Notbob hcold6 years ago
Mmmmmm.... lead dust....mmmmmm.... I'm rather sure it would be lead dust you would breath in, unless you were melting it smooth.. I would think that all you would need to do would be wear a respirator to filter out the dust.
lol I accidentally ate some lead pellet gun ammo and I'm still perfectly normal....Maybe
lead only affects a developing brain in small amounts......
PCB smoke, don't breathe this!
Will it blend? That is the question....da da daa da daa
the only epoxy that i can find doesnt dry clear unfortunetly...
killrsheep (author)  Notbob6 years ago
ill be sure to ask around at school, theres a teacher that makes clearcoating magazine photos a class project, the polymer he uses seems like a good idea, im going to find out what he uses
Maybe before assembly / drilling, you could give it an epoxy or acrylic coat / shell
well its not the best looking board but i take dig. engineering and im deff. doing this one vary cool thanks!
killrsheep (author)  2.3turbostang6 years ago
thanks, glad you liked it
siedpe136 years ago
doesn't really look like a circut board, but more like circut board componets just attached on
killrsheep (author)  siedpe136 years ago
trust me... it is this project would have been a lot easier if it wasnt
sageserver6 years ago
what i would do is put lots of gadgets and gizmos on it like a open curcuit calculator, a working touch screen(hard), binary clocks cool(except people dont really know how to read them), pop up fan, laser pointer, pop up light, mp3 player etc, etc. it would be hard to make it but you can probally sell it for a lot of money. Im going to try and make one.
+1000 +fav
Make more of this kind of stuff
killrsheep (author)  sageserver6 years ago
GO FOR IT!! yeh i wanted to make a binary clock too but the litium battery fell off :( and i think it got lost forever, however im thinking of placing some 9v battery clips on it and some voltage regulators since im taking a course on robotics and instrumentation this semester and im gonna need a 24v supply
im just wondering where you got a pcb that big.
killrsheep (author)  Yerboogieman6 years ago
yeah me too, thing is that im not sure what that thing did before i took its guts out XD.... it was a video controlling thingy with a power button and a floppy drive in front and 4 or 5 camera outputs on the back and some parallel ports "cabinet" type thingy that goes on a shelf-like structure... i guess its the best description i can give apart from the link to a pic i placed somewhere on the instructable
Plasmana6 years ago
Wow! I got to build one of those! That would fit perfectly into my personality! 5 stars!!!
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