Building the Breakout Board
In pictures - an assembly guide for the T41U5XBB.
This guide assumes you have bought the optional assembly kits. Though it should be very similar if you sourced your own parts.
Gather the parts and take inventory.
There should be 2 1x24 sockets, 2 1x40 pin header strips, 1 2x3 pin header, 1 2x6 pin header, 10K trimmer potentiometer and 32 screw terminals.
Install the Pin Headers
Snap off the pin headers from the 1x40 header. You will want 1 1x2, 1 1x3, 7 1x4 and 1 1x6 headers. Use 2 sets of needle nose pliers to break each one off.
If it is crooked like this one, use the following procedure to fix it. Otherwise, solder the remaining pins and then touch up the first one.
This is a little tricky but you are going to heat up the one soldered pin and, when the solder melts, the pressure from your finger on the other side will cause the header to slip into place. Verify alignment. Let it cool, solder the remaining pins from the other end and finally touch up the first pin.
Install the Teensy 4.1 Socket
Verify that the sockets are properly aligned and resolder if necessary. Then solder all the remaining pins.
Install the screw terminals.
You will need 2 rows of 11 terminals and one row of 10. Make sure that the are all even. It may take a little extra force to get them perfectly aligned. You want them to sit flat when installed on the PCB.
Install trimmer potentiometer
If you are installing Ethernet, continue on. If not, you are ready to install the grblHAL firmware.
Installing the Ethernet Kit
Take care when soldering the header on the Teensy 4.1. Use the smallest soldering iron tip you have. Avoid over heating the Teensy 4.1. If it is taking too long, stop, let the Teensy cool down and start over. Once one pin is soldered and the alignment looks good, carefully insert the Teensy into the sockets and guide the 2mm socket into the 6 holes on the PCB. A small screw driver can be used to align the 2mm socket pins. Gently press into place. Then solder the remaining 5 pins on top.