16mm

30% built with 16mm switch spacing

Same schematic as the Gherkin, running the same firmware.

16mm is about as close as you can get the switches. There is a small gap horizontally, but vertically the switches are touching. Will have to test with other MX style switches. The milky white Gateron are a little narrower (15.35mm). Gateron beige SMT RGB are the widest (15.65mm).

Using the modified keycaps that were cut down with a Dremel cut off wheel.

This version of the PCB has one flaw that needed to be jumpered. Will also be making a PCB plate so that plate mount switches can be used.

Typing on this is weird. It feels very cramped, it may be different with a different style keycap. I will try a set of cut down DSA keycaps which has more space between the keys. It is much better than the microswitches on the Flanck.

Minimal gap between the switches

Green LEDs installed inside the switches.

Size comparison with a full size Gherkin.

Copper Gherkin

Gherkin bottom plate with copper logo

An experiment with the copper layer on the bottom PCB. The soldermask was sanded off to expose the copper beneath.

It looks pretty good. The copper layer is much higher resolution than the soldermask or silkscreen layers. The copper will eventually patina over time.

Planning to experiment with removing the copper and dying the exposed PCB.

Chopped Gherkin

Gherkin with chopped keycaps

Made a set of chopped keycaps for one of my Gherkins. Some side by side comparison pictures with an identical set of keycaps that are uncut.

Backlighting works well. The LEDs are directional so most of the light is directed at the legends.

White Panda Alien Gherkin Rainbow

Gherkin with Panda switches and Semiotic keycaps

• Gherkin PCB plates
• Invyr Panda linear switches
• Alien Semiotic G20 keycaps from PMK
• WS2812B RGB LEDs 
• Funko Pop Ripley and Alien

White PCB and plates. EasyEDA recently lowered their prices and the price to have different color soldermask. It is now cheaper to order your own sets of PCBs/plates.

The Invyr Panda switches have very little wobble/twist. It is very obvious with the Semiotic keycap legends if your switches are not perfectly straight. I tried them on some Outemu Blue switches and it looked horrible with all the keys crooked. The keycaps look very straight and aligned on the Panda switches.

There are only 10 WS2812B LEDs instead of the 22 I used previously. The WS2812B LEDs are on rigid PCB strips, not the normal flexible adhesive strips. They are otherwise the same spacing as the 30/meter strips.

There are also blue 2x3x4 LEDs inside the switches. They shine up through the slot in the switch tops.

EasyEDA lower prices

Prices much lower, shipping cost the same

It is now $58.09 for 5 sets of Gherkin PCBs with airmail shipping. $38.09 (down from $55.80) for the boards and $20 shipping. That's $11.62 per set, shipped.

If you get 25 sets its $5.76 a set including DHL shipping. $143.84 total, $91.94 + $51.90 shipping

The upcharge for different color soldermask is also lower. $8.21 instead of $10.

I don't think this a special. I don't see any announcement on their site, they did recently change their look though.

How to order a PCB from gerber files.

Gas Guzzling Gherkin

Gherkin with aluminum plate base

• Gherkin PCB
• 6mm M2 Brass standoffs
• 1/4" 2.5x8" aluminum plate
• Vanda-Lay Ind. Drill Press Plus

Found a piece of aluminum plate just the right size for the Gherkin on eBay. First project with my Vanda-Lay drill press. Drilled the holes with a 5/64" bit. Just the right size for 2mm screws (1.984mm). Drilled out the bottom of the holes to 1/8" to hide the screw heads. The hex head nylon screws I had were slightly larger than 1/8" so I pounded them in with a mallet. They are very snug.

The aluminum pieces I bought were saw cut, they had very precise square edges. Sanded the edges and surface down with 220grit and then a scotchbrite pad to give a nice even finish.

Total weight with keycaps is 365grams.

Low effort Gherkin firmware

Using qmk.sized.io to create firmware for a Gherkin

• http://qmk.sized.io
• https://github.com/di0ib/Misc/blob/master/basic.json

Download the json file (click Raw and then save as file). Go to http://qmk.sized.io and upload the json file. The Wiring and Pins tabs are filled in and complete. You will need to complete the Keymap tab and anything else you want to edit.

I was going to create the same keymap as I have in TMK, but the clicking got tedious. Not my way of programming. This will however be useful for anyone who can't create a working dev environment to natively compile the TMK firmware.

Gherkin in the wild

First real Gherkin I've seen

The Gherkin Pi by /u/willbill642.

I have seen a few boards built with the Gherkin PCBs, this is the first one that did something really different.

With this I consider releasing the gerber files as opensource a success. The PCB's are simple and cheap enough to try out new ideas.

I am looking forward to seeing what else the PCBs are made into. The cost to have your own PCBs made are relative low ($16 per set of plates shipped to just about anywhere) and you can sell the ones you don't use.

Ordering a PCB

How to order a PCB from EasyEDA.com from a gerber file

• Download the zip file with the gerber files

The zip file contains multiple files each for a different layer of the PCB front/back. Do not edit these files. They have been tested as they are.

• Go to EasyEDA.com and click "PCB Order"
• Create an account or login
• Upload the Zip file
• Edit the length and width
• Set the quantity, 5 piece minimum per board.
• Set the color (anything other than green cost more, it's a flat fee regardless of quantity)
• PCB should be 1.6mm. With only soldermask (no copper/silkscreen) the PCB will be 1.52mm thick.This matters if you are making a PCB switch plate for MX style switches.
• Leave everything else at default
• Add to cart
• Repeat for additional boards
• Checkout 
• Select airmail or express (usually DHL). Airmail is only an option for lighter orders.
• They take PayPal or credit card
• The video below goes through all these steps.

The price of each individual board goes down dramatically with quantity. The cost of shipping also goes up dramatically, PCB's are heavy. Play with the quantities, you may be able to get many more boards for a few dollars more.

EasyEDA ships to most countries.
For an order of 5 sets of Gherkin PCB's it is $20 to most places via airmail. A total of $75.80 shipped ($55.80 for the 5 top/bottom/main PCBs)
5 mf68 PCB's are $28.60 plus $17.40 shipping, $46 total to most places.

EasyEDA has since lowered their prices.

Order PCB from gerber files from di0ib on Vimeo.

Gerber files I have released:

• Flanck mini 6mm tactile switch
• Gherkin with PCB top/bottom plates
• GNAP keyboard
• i75 keyboard
• Kwark keyboard
• Magicforce replacement PCB
• Nano keypad
• Pico keypad
• Planck compatible PCB top/bottom plates

Gerber files released under https://creativecommons.org/licenses/by-sa/4.0/
You do not have to contact me for permission, the license is comprehensive. You can link back to the github page as an attribution.

Gherkin Wood

Wood case for the gherkin keyboard

• Bamboo plywood
• M2 spacers
• P2 size EPS file for ponoko.com

This is a simple sandwich style case cut out of 2.7mm bamboo plywood. I had two sheets cut, one from the blonde color and one from the darker colored wood. You can see two layers of the darker wood from the side. This would work with 3mm acrylic as well.

Overall it came out ok, but If I did it again I would pick a different material. The bamboo frays and splinters very easily. Ponoko only has veneer and plywoods. www.outfab.com has some nicer solid woods.

You can see the 2 darker layers of wood. There are a total of 6 layers.
I had to sand the edges down to remove the laser scorch marks and to gets all the layers to line up as a single smooth surface.

The cutout for the USB connector. I glued the middle layers together to add strength and to keep them aligned.

The bottom. You can see the frayed edges of the wood where the bamboo veneer splintered.

The edge of the bamboo looks more interesting than the top and bottom surface. It is all bamboo plywood, no fillers.

White LED back lighting. Cheap PBT doubleshot keycaps from eBay.

Bottom removed. Here you can see the PCB fits snugly inside the wood layers. The M2 spacers sit in the holes.
You can see, on the inside, how dark the scorched edges of the wood were.

Sea Cucumber

Gherkin with Fosen Aquamarine and Nantucket Selectric

• Gherkin keyboard with PCB top and bottom plates
• Fosen Aquamarine clicky switches
• Nantucket Selectric SA profile keycaps
• 1.8mm red LEDs