Welcome to the Sumo11 Expansion Board Step-by-Step Assembly guide
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Stage One - Small components
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There is a technique to building this board that will make things go easier. Because of how many components had to be placed in such a small area, if you don't install them in some kind of order you may end up having to solder in some really tight places.

Components needed:
1 - 74HC373 .......................................................................(74HC373)
3 - 1K Ohm Resistors (brn blk red gld) ............................(R1, R4 & R6)
3 - 10K Ohm Resisters (brn blk org gld) ..........................(R2, R5 & R7)
1 - 3.83K Ohm Precision Resistor (org gry org red red) .(R3)
2 - 0.1uF Polyprop Capacitors (104) .................................(C2 & C4)
1 - 4.7uF Tantalum Capacitor (4J7) ..................................(C1)
1 - 0.0068uF Polyprop Capacitor (682G) ..........................(C3)
2 - 2N3904 NPN Transistors .............................................(Q1 & Q2)
1 - ZTX614 Darlington Transistor ....................................(Q3)
3 - 8 Pin Female Headers ..................................................(Digital Inputs)
3 - 7 Pin Female Headers ..................................................(Analog Inputs)
3 - 2 Pin Female Headers ..................................................(Digital Outputs)
2 - 2 Pin Female Headers ..................................................(R-IR & L-IR)
1 - 14Pin Female Headers .................................................(LCD Port)

a) The very first thing that needs to be done is to install the one IC that doesn't get a socket. The 74HC373 octal latch gets soldered directly to the board and will be hidden under the memory chip when done. This chip has a notch on one end and must be aligned with the silk screens notch. Since this chip is being soldered direct, you need to use extreme caution as to how hot you get the chip during soldering. If it's too hot to hold your finger on then you need to let it cool for a bit before finishing.

After you've installed the IC, it's best to get all the small stuff in. The sockets and chips will be the last to get installed. It is VERY important that you install the big memory chip after everything else is done. Memory can be damaged just by touching the pins with your hands, so try to avoid touching them. Keep it in it's shipping package until you're ready to install it.

Here's a picture to give you an idea of how the resistors will get installed on this board as opposed to the main board.

b) Install the 1K ohm resistors at R1, R4 and R6

c) Install the 10K ohm resistors at R2, R5 and R7

d) Install the 3.83K ohm resistor at R3

e) Install the 0.1uF caps at C2 and C4

f) Install the 4.7uF tantalum (tear drop shaped) cap at C1. Pay attention to the polarity, the + side goes toward the LCD port.

g) There is one larger Capacitor marked 682G that gets installed at C3

h) Now install the two 2N3904 transistors at Q1 and Q2

i) The ZTX614 transistor goes at Q3

j) Next you'll need to find a good sharp serrated knife like the one in the picture below or even better would be an Exacto knife with a saw attachment. In your kit you'll find two sticks of Female headers, they both need to be cut up into sections before they can be installed onto the expansion board.

Click on image to enlarge

It is very important that you cut them exactly as shown to get all the pieces needed. With a serrated knife you can cut them in a sawing motion and get a cleaner cut without messing them up.

k) Once you've cut all the headers, you can start soldering them into the board. The three 8 pin headers are for the Digital Inputs, the three 7 pin headers are for the Analog Inputs, three of the 2 pin headers are for the Digital Outputs, two are for the right and left IR and the 14 pin header is for the LCD Port.

Your board should now look like the picture below.

Click on image to enlarge

There are no test that can be done at this time, so you can now move on to stage two of the expansion board assembly.