Instructables on modding an old school cassette player boombox to play your iPod.
Aiwa boombox
JVC boombox
Phillips boombox
Sony boombox
Instructables on building a charger for your iPod.
Super Simple
Famous MintyBoost
YAN9VUSBC
iCylinder
These are all great Instructables. Unfortunately, I ran into some snags and wanted to add a few more features. So, my Instructable covers how I solved some of those problems. I hope this will help others who've run into similar snags or want similar features. Lastly, I had many "do-overs" with this mod and wanted to motivate other modders not to give up on their projects. If you have the courage to tear apart something you just modded, you'll end up with something you can be proud of.
Background:
I started with a Sony CDF-8, an old school combo cassette tape, CD, AM/FM radio boombox. What I wanted in the end is an integrated iPod docking cradle that would both recharge the iPod and play through the docking connector Audio Line Out. I wanted to add a compartment where the old tape mechanism resided. Lastly, I also have a Motorola SLVR L7 iTunes phone so I wanted to add an aux Line In jack.
I've broken this Instructable into segments based on the features I added and the things I learned. I've skipped over most of the basic stuff since the above Instructables do a great job of explaining all of that.
Sorry, I didn't write this Instructable for newbies. The details aren't included. I glossed over things assuming the reader had some previous modding experience. You'll note most of the photos I've included are after the fact. I didn't take any before photos since I wasn't planning to make an Instructable. Without the photos I couldn't include details needed for a neophyte to tackle this mod. Therefore this is more about Hints and Tips rather than a true step by step.
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Signing UpStep 1HINT - HOW TO FIND A "CLEAN LINE IN"
Here's a hint to make your hunt easier. Most of these boomboxes have a mechanical selector switch that switches the source from the CD player, radio or cassette tape to the main amplifier. Find this selector switch.
After you find the switch, flip the main board over and locate the correct pins for the cassette tape player. I was lucky, mine were labeled.
The switch is dual pole, one side for the left channel, the other for the right. Follow these traces to a spot where you can solder on some leads. Mine happened to end up on two jumper wires on the parts side of the main board which makes soldering real easy. On my mod, I wanted to run this "clean line" to both the iPod and an Aux. Line In. Therefore, I wired a pair of leads to this spot. Where do these leads terminate? One L&R pair can be soldered and heat shrunk to the 1/8 stereo line in jack, the other L&R pair to be wired to the iPod, See STEP 3.
Why is this line "clean?" Because it bypasses the cassette tape player's preamp and associated circuitry, which was designed for a tape head not the headphone output of an iPod. If you connect your iPod to these lines and adjust the iPod volume, chances are you'll get a much cleaner sound than using the "cassette-tape-head-method." Booya!
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I really doubt that the circuitry is sophisticated enough to sense motor movement or motor load. It's just a tape cassette drive but I guess it is possible.
Hmm, what else. Did you find the reed switch I mentioned Step 4, third photo? That may need to be closed/shorted to turn on the amp.
When you switch the function selector switch to radio, does the radio work?
I also ran across an Instructable called "Ghettoblaster MP3 player installation". Check it out because it is a Panasonic mod. You may see something in there to help debug your problem.
Sorry I couldn't be more help. : (
Sounds great! Thanks for writing this though. It inspired me to bring new life to my mid 90's boombox instead of spending $150 on a new boombox with comparable sound quality.
As with most things, I am speaking in general. There are exceptions.
Hope that helps. : )
Are you sure the pins are actually numbered and connected like this? Both 50K resistors are connected to both pins 25 and 27? Why didn't they just use a 25K resistor? These pin numbers seem to be reversed from yours: http://www.ipodlinux.org/wiki/Dock_Connector
Sorry, I didn't realize my pinout links were broken. Here is the new link. Yes, the 50K resistors are redundant. I didn't realize this until later. A single 25K should work. However, it depends on the model iPod. Refer to the link for specific requirements for your model. Yes, the pin numbering is different depending on the connector. There is a note about it on the pinout page.
I highly recommend the PodGizmo breakout connector from Sparkfun. It is large but makes the modding so much easier! : )
http://www.instructables.com/id/Boom_Box_Ipod_Dock_Homemade_iHome/
How to gain experience? I was lucky. When I was in High School, they offered various shop classes. I took them all and learned about electricity in a supervised environment.
Depending where you live, an option are these new TechShops that are opening around the US.
http://techshop.ws/index.html
They offer classes on soldering, welding, sewing, etc. I haven't attended any of these classes but have visited one and was impressed by both the staff and the facility.
The final option that comes to mind is to find a friendly neighbor/mentor. The person always working on their car or has their own workshop is a good place to start.
Sorry, I couldn't be more help.