BRIAN Construction Manual

BRIAN (Baofeng BF-888S Radio Interface to the Allstar Network) is a kit construction project that implements
a Raspberry Pi hosted Allstar node using the circuit board and other parts from a Baofeng BF-888S as the node
radio operating in the amateur UHF (70 cm) band. An Allstar node can be implemented using BRIAN and a
Raspberry Pi running an Allstar distribution.

Figure 1 - BRIAN Allstar Node

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The BRIAN electronics is housed in an extruded aluminum enclosure measuring 4.72L x 3.07W x 1.06H inches.
The Baofeng “rubber ducky” antenna is mounted to the top of the enclosure. Internally, two daughter boards
– the Baofeng circuit board (modified by the builder) and a Sanwu CM108A Audio FOB (also modified by the
builder) – are mounted to a motherboard which contains additional circuitry and jumper wire connection
points to simplify wiring to the daughter boards.

BRIAN is powered by a 120 VAC to 5 VDC power adapter. The power adapter plugs into a standard DC jack on
the rear of BRIAN. The PC board design contains jumpers so that an optional 12 VDC to 5 VDC inverter can be
installed in the unit to permit operation from 12 VDC.

Two cables coming from BRIAN plug into the Raspberry Pi’s USB micro-B (5VDC) and USB-A jacks. Front panel
LEDs on BRIAN indicate the status of the unit – BRIAN POWER (blue), RADIO POWER (blue), COS (yellow), PTT
(red) and COMM STATUS (blinking green). The 888S circuit board is modified to reduce the output power to 20
– 50 milliwatts…. perfect for a local Allstar node! This modification also reduces the node current
requirements to less than 450 mA.

Figure 2 – BRIAN Motherboard and BF-888S Daughterboard

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 Figure 3 – BRIAN Motherboard and modified Sanwu CM108AH USB FOB

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Disclaimer:

This device contains a radio that operates in the amateur 70 cm band. You are responsible for its proper operation
including frequency, power level and harmonic content. This includes installing, configuring, testing and verifying that
the device performs properly in your environment. The developers cannot be held liable for any direct, indirect,
consequential or incidental damages to other pieces of software, equipment, goods or persons arising from the use of
this device.

By constructing this device you accept the above terms of copyright and disclaimer.

Release Notes:

RELEASE DATE CHANGES

1.00 2019-04-27 Initial release
1.01 2019-04-29 Removed low power mod discussion, fixed typos and reformatted

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Table of Contents

BRIAN Overview .................................................................................................................................................................. 6

Key Features .................................................................................................................................................................... 6
Setting Expectations........................................................................................................................................................ 6
Construction Difficulty .................................................................................................................................................... 6
Required Materials.......................................................................................................................................................... 7
Step 1. Fitting the Motherboard PCB to the enclosure ..................................................................................................... 8
Step 2. Disassembly of the Baofeng BF-888S and Low Power Modification ..................................................................... 8
Step 3. Initial Assembly of the Motherboard ................................................................................................................... 12
Step 4. Modifying and Assembling the FOB Carrier Board to the Motherboard .............................................................. 13
Step 5. Assembling the Baofeng BF-888S Daughterboard to the Motherboard .............................................................. 19
Step 6. Mechanical Preparation ....................................................................................................................................... 23
Step 7. Install the RF Connector ....................................................................................................................................... 25
Step 8. Final Motherboard Assembly ................................................................................................................................ 26
Step 9. Final Mechanical Assembly and Test .................................................................................................................... 29
Step 10. Setup and Test .................................................................................................................................................... 30
Appendix 1. BRIAN Parts List and Board Layouts ............................................................................................................. 31
Appendix 2. BRIAN Schematic Diagram ............................................................................................................................ 34
Appendix 3. Mechanical Cover and Extrusion Drilling Templates ................................................................................... 35

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BRIAN Overview
Key Features
 Uses low cost, proven Sanwu CM-108 USB FOB
 Uses the circuit board from a Baofeng BF-888S UHF radio
 Small, portable with self contained radio and antenna
 Low power modification (20 to 40 mW) to the radio ensures no self generated interference
 Motherboard, daughter board design simplifies wiring
 Rugged RFI-resistant metal enclosure
 Jumpers and extra parts locations facilitate custom configurations
 Plastic end caps to ease the drilling of required holes
 Metal end caps available from enclosure manufacturer.
 Optional 12 VDC operation

Setting Expectations
 What’s missing from this miniature design?
o No display or keypad for frequency selection. Rotary switch selects one of 16 preprogrammed
frequencies
o UHF (70 cm) only
o BF-888S radio receiver is degraded by strong nearby frequencies

Construction Difficulty
 Degree of soldering difficulty – Difficult to Medium
o Difficult Part- Modifying the USB FOB requires soldering six 30 gauge wires to tiny pads and IC pins. You
will also be stripping Teflon insulation from 30 gauge wires so you will need an appropriate wire
stripper. You will need a good light, a steady hand and probably need some type of magnification to do
this procedure successfully. The use of the motherboard carrier board does help in securing and
terminating these added wires. Read through the procedure for modifying the FOB and if it seems to be
beyond your skill level consider ordering the kit with the partially assembled motherboard.
o Extracting the Baofeng BF-888S radio requires desoldering and mechanical skill.
o Modifying the BF-888S board for low power requires surface mount desoldering skills. In addition, the
added “white” wire requires soldering to SMD parts and traces.
o Medium Part – Assembly of the DINAH motherboard is standard through-hole soldering of leaded
components.

 Degree of mechanical difficulty

o The BRIAN motherboardboard may fit snuggly in the metal enclosure. You may need a file or sandpaper
to adjust the boards for a snug fit in the case
o You will be drilling holes in the aluminum enclosure and plastic end caps. The locations and sizes are
specified in drawings included in the Appendix. You must be able to read these drawings to successfully
create the required holes. You will also need a precise measuring device such as a dial or digital caliper.

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Required Materials
 Tools
o Low wattage (50 watt) solder pencil with small tip and solder
o Higher wattage solder iron to solder 14 gauge wire for the USB FOB assembly
o Phillips screwdrivers (#1 and smaller), small side cutters, small needle nosed pliers
o Small Torx screwdriver
o Dial or digital caliper
o Wire stripper for 30 gauge Teflon wire
o Eye magnification device desired – especially for modifying the USB FOB
o A drill set with drills in 1/64 inch increments up to 11/32” or a good step drill bit
o A set of small files

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Step 1. Fitting the Motherboard PCB to the enclosure

In this step you will verify that the motherboard PCB fits into the extrusion mounting slots. If not, you will modify the
boards as required by sanding/filing its edges.

The motherboard PCB location in the final assembly is in the

second slot down from the open top of the extrusion. Insert
the PC board and verify that it fits and slides in the slots
(slightly loose). If a board is too tight, use fine sandpaper
(220) or a file to remove material equally from both long
edges of the PCB until you achieve a slightly loose fit. Clean
off any dust you created in the sanding process and set the
board and extrusion aside

Step 2. Disassembly of the Baofeng BF-888S and Low Power Modification

In this step you will disassemble the Baofeng BF-888S, remove the PCB and make electrical modifications to the board.
Note that there have been at least five revisions to the BF-888S PCB. The various revisions resulted in a shortening of
the PCB. The initial design used a “full length” PCB, followed by a ¾ length PCB and then at least two variations of a
“half length” PCB. The BRIAN motherboard is designed to work with the half length variants. Also note that the SMA RF
connector was changed in the latest revisions from being attached to the extrusion with two screws to slipping into slots
in the extrusion in the latest version. To accommodate this change, a new SMA RF connector is available if required by
the version of the radio.

Remove the antenna and battery from the radio (if installed).
Save the antenna for final assembly.

Your radio should now look like the photo to the right. The
labeling may be different. Take note of the shape of the case,
it is different on earlier units.

Remove the two plastic control knobs. The longer knob fits
tightly. Use a flat bladed screwdriver to pry it off if necessary.
Save the knobs for final assembly.

Remove the two Torx head screws and the two Phillips head
screws. Remove the three brass nuts with slots used on the
antenna jack, volume control and frequency selection switch.

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Remove the cast chassis and PCB by lifting the casting out of
the plastic enclosure at the end which was held by the Torx
screws. Position the two pieces as shown and unsolder the
two speaker leads at the PCB. Recycle the speaker/plastic
enclosure.

Refer to the picture to the right (magnified below). Remove

the LED by cutting its two leads (yellow rectangle) and recycle
it. Remove the microphone (yellow rectangle) by twisting it
off with alternating circular motion. Discard it.

Referring to the cyan rectangles, remove the three PCB

mounting screws and the two RF connector mounting screws
(if used) and save for possible use later. Use solder wick or a
solder sucker to remove the solder on the center pin of the RF
connector and the power connection to the board (red
rectangles) and remove the board from the casting. Save the
RF connector for later assembly unless it has no screw holes
as described at the beginning of this section. Recycle the
casting.

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This is the BF-888S PCB assembly with the LED removed, the
mic removed, the RF connector removed and the solder
removed from the antenna center conductor and DC power
connection points.

In order to avoid possible RFI interference from the nodes transmitted signal back into the audio you receive from your
node, we recommend modifying the Baofeng BF-888S board to reduce the output power. The following modification
reduces the RF power output from the 0.5 to 2 watts level to a level of 20 to 50 milliwatts which is ideal for a local node
for use in a mobile application or locally around your shack. The low power modification also removes the risk of your
radio being damaged by excess heat running at a near 100% duty cycle as an Allstar node. If you do not do this
modification, you may find that you hear interference on the audio that you receive from your node. If you do not do
the modification and you have interference, using a remote antenna (not the rubber duck) located away from the node
may minimize or cure the interference problem. Also, you always have the option of disassembling your node and
performing the modification if the interference occurs.

Proceed with the following steps to do the low power modification to your board.

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Unsolder and remove the 3 parts outlined with red rectangles
in the photo. These parts are (enter rectangle) the final
amplifier transistor (PA), the choke (coil) feeding DC to the PA
to the right of the PA and a tiny SMD part to the left of the
PA. The use of two soldering irons and steady hands works
well for this task. A hot air rework station works even better!

Fashion a jumper wire from the 30 gauge Teflon wire and

solder it as shown in the photo. One end solders to the pad
exposed by removing the PA DC feed choke and the other end
solders to the ends of the two SMD capacitors as shown.

Set the completed assembly aside for later installation on the

daughter board.

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Step 3. Initial Assembly of the Motherboard
In this step you will assemble parts onto the Motherboard in preparation for installing the two daughterboards. Each
part to be installed will be shown enclosed in a red rectangle in the photo to the right of the text description.

Install seven resistors as shown:

R1,R5,R7,R8 – 10K
(BROWN,BLACK,ORANGE)
R2,R3 – 390 OHM
(ORANGE, WHITE,BROWN)
R4 – 1K
(BROWN,BLACK,RED)

Note: There is no R6 on the board

Trim all leads after soldering and save

them for later use.

Install ten 1 nF capacitors as shown:

C1,C2,C3,C4,C5,C6,C7,C8,C9,C10

Trim all leads after soldering and recycle.

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Install D1. Trim leads after soldering.

Fashion a jumper from one of the leads and

install between E1 and E3.

Note: There is no D2 on the board.

Install D3. Trim leads after soldering and

recycle.

Step 4. Modifying and Assembling the FOB Carrier Board to the Motherboard
In this step, you will mount the Sanwu FOB onto the motherboard and solder six jumper wires from the FOB to the FOB
carrier board. This requires a steady hand and excellent eyesight (or an optical magnification device).

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Modify the Fob by removing the MIC
and SPK 3.5mm TRS jacks, R7 and D1
as shown in the photo to the right,

Cut four 30 AWG solid core Teflon

jumper wires and solder them to the
following pins/pads on the FOB

PIN 13 (PTT) of the CM108AH

PIN 48 (COS) of the CM108AH
PIN 15 (GPIO4) of the CM108AH
D1-R5 PADs (GREEN LED ANODE)

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Use the provided 0-80 screw and nut
to temporarily attach the FOB to the
motherboard, passing it through the
hole (yellow rectangle) next to the SPK
silkscreen label as shown.

Insert two ½” lengths of 14 AWG bus

wire in the two holes (orange
rectangles) closest to the end of the
FOB as shown.

Turn the motherboard over and solder

the two 14 AWG wires to the pads.
Ensure that there is sufficient wire
length protruding through the FOB on
on the other side to permit the
soldering operation described in the
next step.

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Locate one of the wire leads saved
from the installation of the resistors.
Solder it to the four pads and two 14
AWG wires at the end of the FOB as
shown (red rectangle). Trim all excess
lead lengths after soldering.

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Use four of the wire leads saved from
the installation of the resistors to
fashion jumpers and install them from
the four USB connection pads on the
FOB to the appropriate pads on the
motherboard as shown in the photo.

Remove the 0-80 screw and nut used

to hold the Fob during assembly.
Recycle!

Solder two 1 ½ inch, 30 AWG jumper

wires to the MIC and SPK pads on the
FOB. Route all six wires through the
two holes in the FOB as shown.

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Cut, strip and solder the six wires to
the appropriate pads on the
motherboard as shown.

PTT = CM108AH, PIN 13

GPIO4 = CM108AH, PIN 15
COS = CM108AH, PIN 48
GRN LED = D1-R5 PADS
SPK = SPK
MIC = MIC

HINT: Melt a pool of solder on each

pad and let it cool. Place the stripped
wire onto the solder. Apply the tip of
your soldering iron to the wire and
push it down into the solder.

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Step 5. Assembling the Baofeng BF-888S Daughterboard to the Motherboard
In this section, you will install the Baofeng BF-888S daughterboard onto the motherboard and connect jumper
wires between them. You will also install a male connector pin for the antenna connection.

Prepare a 1 ½ inch piece of 30 AWG

solid core Teflon wire and solder
one end to pin 1 of the IC on the BF-
888S board as shown in the photo.

Mount the Baofeng board to the

motherboard using five 2-56 x ½”
screws and nuts. Use five 3/16 OD x
.094 ID x ¼ Long aluminum spacers
between the boards. As you place
the board, route the wire soldered
to pin 1 in the previous step through
the unplated hole (not labeled)
beside C7 (note red rectangle on
photo) . Tighten the five screws and
nuts securely.

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Using solid core 30 AWG Teflon
wire, solder four jumper wires to the
points shown in the photo (PTT,
COS, VOL, PWR). Route the wires
through the appropriate unplated
holes in the mother board and trim
to the length required to connect to
the appropriate labeled pads on the
back side of the motherboard.

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Solder the five wires to the
appropriate labeled pads on the
motherboard. As was done in the
installation of the FOB, melt a pool
of solder on each pad and let it cool.
Place the stripped wire onto the
solder. Apply the tip of your
soldering iron to the wire and push
it down into the solder.

Locate the male connector pin.

Solder it into the antenna
connection pad on the Baofeng
board. Make sure it is centered
when looking at it through the
unplated clearance hole in the
mother board. Cut the top portion
on the pin off at the white line as
shown in the following two photos.

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Use one of the cut leads from the
resistor installation on the
motherboard to install a jumper
between the motherboard and the
DC power connection on the
Baofeng BF-888S board as shown in
the photo. The connection on the
motherboard is labeled E11 but is
not visible once the BF-888S is
installed. The plated through hole is
on the motherboard directly below
the connection point (plated hole)
on the BF-888S

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Step 6. Mechanical Preparation
The next step in electrical assembly is to connect the USB and USB power cable that connect BRIAN to the Raspberry Pi.
Since these cable pass through the rear panel, we need to drill the required holes in the rear panel. So in this section we
will drill the required holes in the front and rear panels as well as the extrusion cover.

Referring to the photo at I suggest you invest in a set of calipers (Harbor Freight? Or hamfest) and use the “inside”
the right of the rear panel measuring capability to scribe dimensions onto the plastic.
and the detailed drawing
in Appendix 2, drill the
five holes for the DC
Power Plug, the two
control shafts and the two
USB cables. Note that the
dimensions on the
drawings are for a view
from the inside of the
cover. This allows you to
make scribe marks on the
cover.

Referring to the photo at

the right of the front
panel and the detailed
drawing in Appendix 2,
drill the five holes for the
five LEDs (left to right)

COMM OK
PTT
COS
BF-888S POWER
BRIAN POWER

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Referring to the picture at Also, the 2 small mounting holes are shown as tapped to a 2-56 thread. If you do not have
the right and the detailed this tap available, you can drill the holes larger (3/64”) and use nuts on the screws (difficult
drawing in the appendix, final assembly). Or you can use the 2 screws that were used to hold the connector in the
drill the holes for the RF BF-888S (not as pretty).
connector. Note that this
picture is taken of the
inside looking out. It is
also only applicable to the
BF-888S which has an RF
connector with mounting
holes. If you have a
connector with a square
flange and no mounting
holes, the pattern will be
TBD. Also, the 2 small
mounting holes are shown
as tapped to a 2-56

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Step 7. Install the RF Connector
In this step you will modify the RF connector and install it to the extrusion cover. This assumes that you are using the RF
connector that you removed from the Baofeng BF-888S radio. If you have a connector with the square flange, you will
be using a different TBD connector and these steps are TBD

Locate the RF connector that came with your radio.

Straighten the center conductor and cut it to 0.25 inches
long.

Locate the female pin and solder it to the center conductor

of the connector. A suggested method is to clamp the pin in
a vertical position. Then insert a piece of solder into the pin
wire cavity. Cut it off so it is slightly below the top edge of
the cavity. Hold the RF connector with the center conductor
resting on the solder and use a soldering iron to heat the
center conductor and the top edge of the pin cavity until the
solder melts and the center conductor is fully bottomed in
the cavity.

Install the RF connector onto the extrusion cover using two

2-56 screws (or other screws and nuts per previous
discussion). Slide the rear cover onto the extrusion and
slide in the cover extrusion. If your RF connector is located
correctly, you will find a slight interference between the RF
connector and the end cover. Use a file or sharp knife to
create the required clearance as shown in the photo.

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Step 8. Final Motherboard Assembly
In this step, you will complete the assembly of the motherboard

Install the DC Power Jack – J2.

When installing it, strive to keep
the front surface even with the
edge of the board and parallel to it.
We suggest you lightly solder one
terminal and check alignment
before completely soldering it to
the board.

Locate the USB cable (USB –A on

one end and USB micro-B on the
other). Cut the cable into 2 pieces
with the USB micro-B end being
about 4 inches longer. Thread
cable with the USB micro-B
connector thru the hole in the rear
cover nearest the center of the
cover (refer to previous photo of
rear cover) from the outside to the
inside of the cover. Strip about ¾
inch of insulation from it. Remove
the metal foil and cut off the green
and white wires. Twist the shield
wires and insert this twisted shield
into the hole labeled shield (near 5
VDC PWR TO Pi). Solder the shield.
Install a cable tie to hold the cable
then strip the red and black wires
and solder them to the board in the
labeled holes.

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Thread cable with the USB-A
connector thru the hole in the rear
cover nearest the outside of the
cover (refer to previous photo of
rear cover) from the outside to the
inside of the cover. Strip about ¾
inch of insulation from it. Remove
the metal foil. Twist the shield
wires and insert this twisted shield
into the hole labeled shield (near
USB TO Pi). Solder the shield.
Install a cable tie to hold the cable
then strip the red, white, green and
black wires and solder them to the
board in the labeled holes.

The picture to the right shows the

motherboard after connecting the
USB-A and USB micro-B cables.

Prepare the 5 LEDs (LED1 thru

LED5) as shown in the photo.
Look carefully at the short lead on a
LED and you will see a flattened
spot about 0.1 inches long. Start by
bending the short lead of the LED
first. Make the bend at the end of
the flat spot nearest the end of the
lead. Bend the long lead of the LED
so it is about 0.10 inches farther.

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Solder the 5 LEDs to the
motherboard per the photo to the
right. A suggested method is to
insert each LED – one at a time –
into the motherboard. Working
from the top (as seen in the
picture) align the LED and tack the
right lead (round pad) to hold it in
place. Then turn the board over
and, for each LED, solder the
untacked lead (square pad) on the
bottom of the board first. Then
apply solder to the tacked lead.

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Step 9. Final Mechanical Assembly and Test
In this section, you will perform final assembly of BRIAN.

Install the front cover on the extrusion. The holes for the
LEDs should be slightly below the centerline. Slide the
motherboard assembly into the extrusion fro the rear, 2nd
slot down from the open top, with the Baofeng board
facing down.

Remove the RF connector from the extrusion cover and

slide the cover in from the rear with the hole for the
antenna connector at the rear.

Reinstall the antenna connector making sure that the

antenna connector male and female pins engage
correctly. Reinstall the connector mounting screws.

Slide the rear cover along the USB cables and over the
extrusion. Install four screws in the front and four screws
in the rear cover.

Install the four feet on the bottom of the extrusion.

Install the BRIAN label (location your choice)

Install the knobs on the Volume and Frequency shafts.

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Step 10. Setup and Test

 Connect the USB cables to your Raspberry Pi which has an Allstar distribution installed.
 Connect the 5 VDC adapter to the DC Power Jack on the rear of BRIAN (2mm center pin).
 Set the Frequency selector switch as desired.
 Monitor with a radio on this frequency.
 Rotate the Volume so that the Baofeng power switch is ON (Volume setting does not matter).
 Apply power to the adapter. You should see 2 illuminated blue LEDs.
 Your Raspberry Pi should begin initialization.
 The green LED should begin to blink.

If you are using the HamVOIP distribution and are connected to the internet you should hear your IP address
announced over your radio.

You should also check your output frequency. If can be adjusted using the small trimmer capacitor on the visible
side of the BF-888S board. You can access it by removing the four rear cover screws and sliding the mother board
together with the cover extrusion rearward far enough to see the capacitor. Be careful not to exert too much stress
on the antenna connection to the Baofeng board.

You can also use the above method to provide access to the microphone jacks to reprogram the radio frequencies.

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Appendix 1. BRIAN Parts List and Board Layouts

REF NAME PART NO DESCRIPTION MFG QTY

PC Board BRIAN PC Board JLCPCB 1
R2,R3 Resistor CFR-25JR-52-390R Carbon film, 390 OHM, 5% Yaego 2
R4 Resistor CFR-25JR-52-1K Carbon film, 1K ohm, 5% Yaego 1
R1,R5,R7,R8 Resistor CFR-25JR-52-10K Carbon film, 10K ohm, 5% Yaego 4
R6 Resistor N/A Not Installed N/A 0
C1,C2,C3,C4,C5,C6,C7,C8,C9,C10 Capacitor K102K15X7RH53L2 Ceramic, Radial Leads,1nF,10% Vishay 10
D1 Diode RL204-TP Rectifier Diode, 2 A, 400 Volt MCC 1
D3 Diode BAT43 Shottky Diode, 200 mA, 30 Volt ST Micro 1
Q1 Transistor 2N7000-D26Z Transistor, Mosfet, N-Channel, 60 V, 200 mA ON Semi 1
LED1 Green LED LTL-4231N 3mm, Through Hole, Green Lite-On 1
LED3 Red LED LTL-4221N 3mm, Through Hole, Red Lite-On 1
LED2,LED4 Blue LED VAOL-3LSBY1 3mm, Through Hole,Blue VCC 2
LED5 Yellow LED LTL-4251N 3mm, Through Hole,Yellow Lite-On 1
J2 DC Power Jack PJ-037AH DC Power Jack, 2 mm Pin, 5a, RA, Through Hole CUI 1
FOB1 USB FOB CM108 USB FOB Sanwu 1
Male Contact D-Sub Male Contact, Crimp 22AWG 1
Female Contact D-Sub Female Contact, Crimp 22AWG 1
Wire Wire, Solid, PTFE, 30 Ga Varies 1
Wire Wire, Solid,Bus, 14 Ga Varies 1
USB Cable 3 ft. , microUSB male to USB A male Sabrent 1
Enclosure 1455J1202BK Extruded enclosure, 4.72x3.06x1.07 in. Hammond 1
Spacer Spacer, Aluminum, 2-56, 1/4L x 0.180Dia 5
Machine Screw 2-56 x 3/16", Pan Head, Phillips,18-8 SS
Machine Screw 2-56 x 1/2", Pan Head, Phillips,18-8 SS 5
Nut 2-56, 18-8 SS 5
Radio BF-888S HT, UHF, 2 watts Baofeng 1
Power Adapter 5 VDC, 2A with DC power plug (2mm) Various 1
Label DINAH I/O Aluminized Label Stickers Int'l 1

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BRIAN Construction Manual Page 32
BRIAN Construction Manual Page 33
Appendix 2. BRIAN Schematic Diagram

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Appendix 3. Mechanical Cover and Extrusion Drilling Templates

Front Panel – In Work

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Rear Panel – In Work

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Extrusion Cover – In Work

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