Tweakers' Asylum: Here goes by E-Stat

Parts list:

(1) Radio Shack aluminum project box 27-238 (I think*) $2.99 ea
(2) Radio Shack 50k linear pots 27-1716 $2.49 ea
(1) RS pack of 5-10k 5% carbon film resistors 27-1126 $.99 ea
(1) RS pack of 4-RCA audio jacks 274-346 $2.99 ea
(1) 60' roll 18 gauge solid core wire 278-1217 $3.99 ea (only need about two feet!)
(2) Audio Research silver knobs $18.00 ea ** (any will do!)

Procedure:

1. Mark openings for gain pots 1-1/2" from each side and 1/2" from top on front of project box chassis. Drill pilot holes using 1/8" bit. Follow with 17/64" bit for full size opening.

2. On back side of project box, mark openings for input and output jacks 1-1/2" from each side and 5/8" from top and bottom, respectively. Drill holes using same size bit sizes as before.

3. Using Dremel tool or hacksaw, trim length of gain pot "axles" to desired length based upon choice of knobs.

4. Install gain pots to project box. For each pot, insert from back side into opening on front panel, place washer and affix with lock nut. Orient connectors in mirror imaged pattern to provide clearance for wiring. Bend connection tabs forward. See photo.

5. Install audio jacks to back panel of project box. For each, insert jack, place lock washer, and affix with lock nut Orient connectors with ground tab in mirror imaged pattern to provide clearance for wiring. See photo.

6. Cut (2) lengths of solid core wire to 1-1/2".

7. Cut (2) lengths of solid core wire to 3".

8. Cut (4) lengths of solid core wire to 2-3/4".

9. Strip 3/8" of each end of wire sections.

10. For each channel, attach 1-1/2" length of wire from ground tab of lower input terminal tab (input) to ground tab of upper input terminal tab (output). Fold exposed end of each wire in half and crimp lightly using needle-nosed pliers.

11. Complete left channel wiring. Attach 3" wire section to pin 3 of pot to ground of input jack (lower). Attach first 2-3/4" wire section to pin 2 of pot to center pin of output jack (upper). Attach other 2-3/4" wire section to pin 1 of pot to center pin of input jack. Trim leads on resistor by 1/2" on each side. Attach one end of resistor to center pin of output jack (upper) and other end to ground tab of output jack.

12. Complete right channel wiring. Attach first 2-3/4" wire section to pin 1 of pot to center pin of input jack (lower). Attach other 2-3/4" wire section to pin 2 of pot to center pin of output jack. Attach 3" wire section to pin 3 of pot to ground of output jack (upper). Trim leads on resistors by 1/2" on each side. Attach one end of other resistor to center pin of output jack (upper) to ground tab of output jack.

13. Gently crimp ends on all wiring connections together. Before soldering connections, test out unit.

14. Following successful circuit test, solder all connections. Apply heat to wiring, wait, and apply solder to connections. Allow solder to flow and create bead for each connection.

15. Affix cover with 4-sheet metal screws.

16. Attach knobs to gain pots.

Voila!!!

*Bad timing to get exact part number. I had already matched up credit card receipt via Quicken web and shredded receipt. Today is trash day on my street so I no longer have original packaging!

**Nope, I would not spend $36 on knobs for a $16 project! Just had them left over from a black panel/knob replacement for my preamp.