Zenith ZStar EX

[JKnightandKARR]

  This was a lot of copy and pasting, some editing, but I am working on a Zenith Z-Star EX I got from Granz.

About the device:
CPU: Intel 486 DX2 50 MHz
RAM: 3Mb
HDD: 210 Mb
FDD: 3.25"
OS : DOS 6.20
WIN: 3.10

Issues:
Laptop has a bad/leaking CMOS battery and there is an unknown issue with the HDD making it sometimes not reliable.

Current modifications:
-OPL2LTP V2- An Adlib sound card based on the Yamaha OPL2 chip, purchased from https://www.serdashop.com/OPL2LPT, works well as an alternative to the PC speaker since the laptop lacks a sound card.
-Compact Flash to 44-pin IDE to replace the HDD, so far only failure, device will not even attempt to boot up.
-PS/2 to USB adapter powering a modern laser/optical mouse.  Works surprisingly on the old mouse drivers in Windows 3.1x

Things todo:
-Repair the backup battery
-Fix or replace the HDD issue.

The Laptop


486 CPU, Surprised there is no heat-sink.


Battery holding area corrosion.


Battery, positive wire broke off due to the corrosion


Terminal Corrosion

It's shot.... 4.5 V rated



44-Pin IDE drive, 210 Mb

One of my Compact Flash to 44-pin IDE adapters and my Adlib compatible sound card.

[JKnightandKARR]

  Well I have found possible way for getting the BIOS battery redone.  It uses 4 of whats called 1/4AAA cells. EX: https://www.batterybob.com/products/5962-14-aaa-nimh-rechargeable-battery-14aaa-80nm/, at a place local called Batteries Unlimited, who currently have it.  Also I have contacted the You-tuber, The 8-Bit Guy about my hard drive issue, and possible fix since my Compact Flash adapter will not function.

  Well I guess on the HDD it don't seam bad, but not good either.  It does infact work, checked it with Fdisk or ScanDisk, can't remember which, but it not showing bad sectors or anything, but what it does is it will start acting like its got reading issues, so maybe thinking a short or break in trace or component(s) on the hard drives built in control board.  If I restart the system, drive works again, so strange issue.  As for the Compact Flash adapter, if I swap the adapter out from the HDD, the computer won't even power on let alone boot, and once HDD is reinstalled, system powers up and works fine.

  On a side note, funny to myself anyhow, but I picked up an old laser/optical mouse that was in the trash had USB to PS/2 adapter, and oddly enough, Windows 3.x drives WORK with it just fine!  Did NOT expect that. lol :lol:

  The only other thing I am going to try and do is since the laptop has multiple power ports, never seen this before, going to try and use one to power the OPL2LPT V2 sound card.  Works on its own from the power on the Parallel port, but figure might as well power it properly, as well as possible powered speakers, since it has no built in speakers, not incl the pc speaker.  It's an Adlib device and sounds great! I might as well try and make a 3D printed case for it, or order one from the one who made it.  Anyway, other then that, that is the current status, of my project, sadly no gameports, so no gamepads or joysticks, unless I can find plans to make one using the 9 pin serial port.

[JKnightandKARR]

 
A second adapter, but this uses Micro SD card.
 
Well THAT was fun....... NOT!  Anyhow..... Same thing, no power up....  Wouldn't think it was due to the lack of SD card. should have gotten a drive error.
 
Testing the volts.
 
Once I put bot of my meter on, the volts dropped?? ODD...
 
Did a 2nd test putting the BM786 and the 121GW inline and got diff result, this time, the mA are now 2uA and the 19+v.

[JKnightandKARR]

   
Found batteries to rebuild the mystery batt on Amazon, was 5pk for $11. They are 1/3AAA instead of 1/4AAA, same volts, slightly higher mA and little taller, but that's no issue on either one.

 
Well well well......  WE HAVE LIFE!!  Tried the 44 pin to CF adapter again, multiple attempts and pretty sure it will only go in one spot, so without cutting hole in bottom, NO way to verify it fitting...  So when my SD card order comes in, will put DOS 6.22 on it and go from there.

 
 
When your good, your good!  3d printed holder, fit first time!  Now just need to mark locations for screw holes!

  I used TinkerCad https://www.tinkercad.com/ to create it, using my CF adapter as a basic form to start with.  Uses shapes to create stuff, which can be all modified in a good amount of ways.  Everything is drap and drop, takes a moment to get used to, esp using the ruler and its MidPoint/Endpoint tool, FYI the one shown is NOT the one your using. lol Confusing but once get used to, its not bad.  All axis have size, position adjust and rotation for that axis only, along with a pop up box for some other options for the selected object, solid or hole, color, along with and other options the said object might have.  I installed the part back into the computer, to test function, and success!, but I put the part into the drive holder to mark the screw holes, which come next, just gotta measure the locations, and the screw hole size.

[JKnightandKARR]

Anyhow update time.
1st) Delay in delivery of new 1/3AAA Ni-Cd cells, hope be here soon...  Expected 10/21 to 10/25
2nd) Still waiting for my 512 Mb SD Card in the mail, so far it is expected like 10/25 to 11-8
3rd) Messed with that optical mouse, not sure if its due to the tech or the damaged cable, but in any case, Windows 3.1 don't seam to like it too much from time to time.  Might need to find an actual ball mousey or maybe better a trackball mousey with the PS/2 plug.
4th) Found a copy of that QuarterDeck QEMM 7.x software and manual, haven't tried it yet.
5th) Looked up some info on editing the Autoexec.BAT and Config.SYS files.  Did a little bit of trimming.

Original settings on the 2 files on the mem command as received

REM'ed the CD-ROM commands, to free up memory space.  No drive so why need it right?

Also did this to the PCMCIA card slots to free up more.  Again, no cards, so at moment, useless until have any cards to use.
6th) OK, did a quick search on the possibility of a CD-ROM drive, and INSTANT success if I so choose. Panasonic did a PCMCIA based solution for this, bit $$$, for me anyhow, but maybe in due time.
7th) Did an attempt to locate the type of module used in the RAM slot, so far nada, other then a source to buy a stick, would LOVE to be able to search like Ebay for one, but without knowing what it uses, little hard.  Windows does have a copy of the computers manual in there, however, even it is NO help on the slot type...  May just need to do a buy from the source I have and HOPE it actually fits...
8th) Was going to organize Windows 3.1 menus into a already opened and ready to use look, but with mouse acting up and the J-Mouse not working, going to try some terminal cleaner to see if I can get the key to work as to have a mouse, so FAIL at moment on organizing.
9th) Was looking at the files Granz sent me

Looks like there might be a Windows for Workgroups 3.11 install files, maybe, gotta open and look, but need a copy of DOS 6.22

Edit: found that WinWorld PC website thanks to one of those files, got DOS 6.22 now

[JKnightandKARR]

 
New cells arrived today before I got up!  Now, I can reassemble the battery!  Will retest the thermal link gotta use something to hold my DMM temp probe to it to check the temp accuracy, and other DMM to check the circuit.

 Ok...... I am now TOTALLY CONFUSED!!
I removed the keyboard totally to spray it down with WD-40's Terminal Cleaner, sticky keys, plus J-Mouse not working.  Fixed keys, plus J-Mouse not working, J-Mouse btw is the J key, which has sensors on it to function as the mouse cursor, so YAY!, but NOW on to the subject at hand.....

I found a little clear tab, wasn't sure what it was, SURPRISE! its actually a CR2025 battery.....  Wonder what THAT's for??  The ACTUAL BIOS battery. 
explains WHY it holds memory of the settings for a while, after receiving power.

Replaced with one from one of my diabetic meters.

SSSSSSSOOOOOOOooooooooo.......................  If the OTHER battery is the memory........  then WHAT is THIS pack of cells FOR?  Computer seams just fine without it.... ssssssoooooooo maybe it's not actually needed???

Right now, using an 8Gb SD card from my Elegoo Neptune 2D to try the HDD adapter, so far, struggling to figure it out....  Other then that....

Update on the 8Gb SD card HDD.  I got it working, sorta and not as expected.  After having time trying to figure out how to do FAT16 on my desktop, found easier way.  Formatted partition to 512, 2048, 2048, 2048 and like 1536 Mb.  Put into laptop, it don't see any of it, until I format it from the laptop and then its ONLY just under 125 Mb size drive.  I tried Format c: /f:512 /s (and /f:510000 among other attempts) all fail.  After format c: /s and copy from my boot disk, it works, but restarting just freezes, and won't start unless the boot disk is in drive A...  So nearly success.... but overall not really...

[JKnightandKARR]

Well, nearing the end of the month, and thinking of what the Zenith Z Star EX needed, and what I wanted:
-Fix the hard drive issue
-Fix the battery
-Get the mouse issue fixed
-Sound card
-Optionally upgrade to DOS 6.22 and Windows 3.11
-Go for a larger drive size, if possible.
-Install my games and my favorite Windows S.S.

I guess just start off and just go down the list as I wrote it.
-First off the HDD issue. While playing with things, so far the original drive hasn't acted up at all, so maybe it just needed to get used to free up the mechanical bits a tad, IDK, my thought, so will consider the issue fixed unless problems arise again.
-The BIOS back up battery has been replaced and now no longer having the loss of BIOS settings, so SOLVED! As for the larger battery pack that I thought was the BIOS, I just need to solder the new cells together, and the thermal link, seams to work just fine, might not hurt to replace it with a new same rated, but that's like 5-10 min job, basically solved.
-The first mouse I have, while worked, acted up a tad, so I found an alternate laying around, which seams to work just fine, so SOLVED!
-The lack of sound. Thanks to the person who does the https://www.serdashop.com/OPL2LPT, the installation is quite simple, and there are 2 versions, the OPL2LPT and the OPL3LPT, plugs in, just add a 5v supply, though I noticed it wasn't actually needed, but using anyway. Sound is good and lack of speakers or a good headset is very simple to fix, so SOLVED! I have a headset, just isn't too comfortable, but VERY simple fix.
-I have DOS 6.22 and Windows 3.11, just need to do upgrades, again SOLVED!
-So far my new SD card adapter is missing its 512 Mb SD card, so NOT much I can do about that, so FAILED until the card comes in the mail, which NO idea how long that will be since I found out, it is coming from China. HOWEVER, the adapter itself DID work, and created a 3d printed case to put the adapter into. I just need to create 5 holes for the drive mount screws, only 3 are in the original drive, so no big issue to reprint a new one with holes added, so over all out of the 3 parts to the replacement drive, the Card, the Adapter, and the case, FAILED!, SOLVED!, SOLVED!
-Last part being games and my favorite Screen Saver, I have games galore and all I need todo is transfer them to the device, EASY AND SOLVED!

So overall I consider this project basically a SUCCESS since, it does work, I can use it, and not really have any issues, so with days left, I can install some games, upgrade some stuff, that is not needed, and a back up of some of the stuff already on there. I am happy, about the progress and what has been done, and only one is really out of my control is the 512 Mb card, the rest is fairly quick todo's. Last few days I can, do some of the other things to really finish it.

 
SSSSSCCCCCCOOOOOOOOOOOORRREEEEEE! 2 for the price of 1!

 
I can tell already, this will NOT be fun.....
 
I was wrong.......  That was actually LOADS OF FUN!!!  NOT!!!!!
 
Well, installed in new bay.  Sadly it will NOT fit in the original location.
 
Well, quick test and ALL seams A-OK!

UPDATE: 9/30/24- Since I have a battery spot welder now, I want to fix the job I did awhile ago, and make the battery fit MUCH BETTER then it currently does!

  In other news, the SD cards DID work, and to the desired size, HOWEVER, I think I still need to learn something, as I got the files from the boot disk to drive C.  Had to remove the partition for the card to be recognized, everything seamed ok, but the card still isn't booting to C.  OH well, will learn somehow, only way to learn is to fail, right?

  Also I need a way to keep the sd card adapter installed into the plastic holder.  Removing the holder leaves the adapter in the port.  Lastly I got my Johnny Castaway Screen Saver, installed. just gotta figure how to make my sound card to work in Windows, since its Adlib compatible, maybe an Adlib driver will work??  Also going to concider the OPL3LPT sound card, since it has a FM chip, or so it says.

[JKnightandKARR]

Still adding more information and doing some editing of it all, more coming tonight.

[JKnightandKARR]

  Ok, got some more updates.

Managed to adjust the Config.sys to get DOS ver of EMM386 working, as a result the OPL2LPT now is installed, DOS anyhow, and apparently not all games support it, so I guess its, a take what I can get thing. Also PRETTY EXCITED, but decided to go after the software for the cards source code, which is available, and also a search for an Adlib Windows driver source code, and managed to locate files for Adlib Win 3.1/3.11 on the OPL2/3LPT cards!!  so going to snatch the source code files for it all, and I think I located actual builds of the Windows drivers, so maybe soon Windows will have sound!  As for games, I have Outrun, pc spkr, Lemmings, FX but no music, Wolfenstien 3D, full sounds!,and a Chip n Dale Rescue Rangers game, pc spkr, and my favorite, sadly without sound is my Johnny Castaway screen saver, better to see then a photo!

 
Testing games out, Playing Wolfenstein3D, sound has to be adjusted EVERYtime so far, but still working pretty good.

My ALLTIME favorite screen saver! Johnny Castaway, actual name is Scrantic or something like that.

About the ONLY thing I have no control over is lack of a 15pin connector for joysticks or gamepads, but who knows maybe there is a way todo something similar to an NES controller only on the unused 9 pin serial port.  I have one lead, so will start there!  I guess this being the last day, other then my SD card drive issue, i guess this project is actually done!

 Well 30 min to Nov 1st, so this is defiantly the last post, so again, one at a time.

Total things done:
-Battery, rebuilt and working.  It won't fit into the original holder, but can always attempt to redo it later.
-BIOS battery replaced.
-HDD seams to be working, so maybe just needed some use.
-J-mouse key working now.
-Did some reworking on the Autoexec.bat and Config.sys files.
-OPL2LPT card drivers installed and working.
-Mouse replaced and working as expected.
-SD card adapter holder created. Needs minor adjustments, but works.
-Found 2-512 Mb SD cards, got set up and files transferred to it using laptop, but will NOT start as primary drive or by using boot disk in A:.  Unknown reason(s).
-Few games on the system, Wolfenstein3D, Lemmings, Outrun and Chip n Dale Rescue Rangers(CDRR) and a bunch others I need to try.
-More usable memory.
-PKunzip installed and a screen shot app
-Found some drivers to possibly get parallel port sound card to work under Windows 3.1
-Have DOS 6.22 and Windows 3.1 Upgrade files, along with other apps and games.
-Have my Scrantic Screen Saver installed, AKA Johnny Castaway.

Other thoughts:
I really wish I could have gotten the SD card drive to work, as more hard drive room would be great, will try and locate a 512 Mb, or maybe a 1Gb 44-pin HDD to use for moment.  Eventually going to DOS 6.22 and Windows 3.11.  Too bad I don't have time to try the Windows drivers for the OPL2LPT sound card.  Sadly not all games so far support the sound card, so I ether have no sound or PC speaker sounds on some games, such as the CDRR game and Outrun are PC speaker.  I have books for using the Parallel and Serial ports, going to attempt a DIY serial port joystick or gamepad.  Also thinking of an external battery pack to power it instead of just AC.  Sadly NO secondary HDD is possible.  Wish I could get a RAM chip to install for more RAM. Want to pick up a PCMCIA based CD-ROM to have for it, along with arranging files on it as a sort of HDD use.  I think that is about it, so with just 3 min left, this project ends now.

[JKnightandKARR]

Aaaaaand then Nov 1st....
OMG!!!!!! YOU HAVE GOT TO BE JOKING!!!!! ALL of that work litterally for NOTHING!!!!!!!!!!!!!! I powered the laptop up to show my girlfriend..... the *CENSORED* hard drive went totally OUT!!!!! NO, screen, and all I hear is the head smacking back n forth..... What the *CENSORED* What a waist of time!! Rant Off.......

  https://www.ebay.com/itm/193941094197
Well, not much luck, but found and ordered this 810Mb drive...Honestly still VERY annoyed at this....  I REALLY hope that this fixes it, but maybe an adapter for my desktop will allow me to get a few files...
 
New 810Mb drive

New drive n the old drive, new bit taller.

Tight fit, but its in place.

Well, screen is back on, however its stuck like this, guess take it home n fiddle with it, maybe try sd card again, just to try and upload new bios, hope its right
This drive was a failure, but the guy sent a 2nd drive out as this was non-working too. 

 
It's alive again! 328Mb hdd, Smaller then I wanted,but at this point I will get what I can take.

Success! DOS 6.22 Now installed

 
Windows 3.11 for workgroups and J-mouse & Ps/2 mousies are back!
Little trouble with my Johnny Castaway screen saver...  Just have to work on my audio card drivers, was thinking of a main menu, and or course games.  Until I can get a cd rom drive, kinda pointless for the PCMCIA drivers since I can't test them.  Few misc things I think.

Well, little bit of an update, I have my screen saver back up, I just need to figure out my audio device again, and then might try and figure out how to power the audio card off of the system, since it requires a 5v power supply, and needing 2 cords is a bit much. Maybe the PS/2 power can power mouse and the audio card?? IDK, I know there are still extra power ports on the system, have to see if any output power, and go from there. Also the J-Mouse is working but the buttons to click don't seam to work, not sure why. For now other then just got 3 packs of disks in for $13 each, that's it for now.

JWell justr a very quick update. I know how to click now with the J-Mouse.
Speed Adj: Hold J +1 to 0, 1=slowest and 0=fastest
Left click: Hold J + F or Space Bar or G for double click
Right click: Hold J+D
Middle click??= Hold J+S? Not sure since don't have the manual anymore
Hold J+E and Hold J+R Not sure what they do Have to Experiment, but the 2 buttons that look like should be the mouse buttons do nothing... oh well least I know how to click now.

Well, it's official. I am now back to where I was when the drive failed. Audio is back, I have my screen saver going, and Wolfenstein3d is back. So FINALLY ready to continue on.... I have also been screwing around changing the DOS screen colors, not fun with the prompt and $e[xx;00;11 stuff..... ESP when for some STUPID reason, I have to run another color change code, just to get the black background with green text.... makes no sense, but whatever, if there is a MUCH EASIER way, I AM ALL EARS!! Meantime, working on a main menu.bat file to display a crude graphic menu for it, gotta use Windows note pad and char map in 3.11 to make it, and see DIFF character from what I expect, but I guess will have to just get used to that..... couldn't figure out how to get the special characters in edit.... OH well, at least I have the ability to continue on.... NEXT plans besides software, is to backup system files, and then use my 3d printer to make a custom docking port for the backside, to let me have the backside alittle cleaner, and maybe see about a custom battery pack for it.

[JKnightandKARR]

 

This is what I am getting, everything that i can color chance in 4dos i did.

Edit: New vid..... THAT one was SOO blurry to really see anything..

Probed my systems power ports, and both output the line voltage, so if I want to make a rear docking station, I can just need some measurements of stuff on back. I want to make it hold the USB to PS/2 adapter, sound card w/5v+ supply for card, and batts for the system itself. Should be able to locate a board to balance the systems power cells easy enough, might need male and female ps/2 connectors to make mouse connection shorter. Can just use unused port screws to hold it on. Pretty simple.

The parallel port card I have works, for the most part, but drivers and support are lacking. For example, Windows 3.x is NOT supported, but Wolfenstein 3D has audio, but not Outrun.

 
Well gotta update, I won a prize! On another update, i have an extention for the hdd port so I can use an IDE DOM in it as well.... I just wish I could take the bottom off of it to acces the port to make installing the cable 50x easier....

 
Well been playing with the old systems today. Noticed the power jack on the back of the system is directly connected to the 20ish volt 1.5A power supply, so should be able make a batt pack and add charger to work directly off that.  Might need to have the exp on the back tall to make more room for batteries.  Next, thanks to Granz, I have an easy way to change colors as I want, least its easy, wish the C:\ wasn't c:\ and the color gets a tad darker but 95% happy with that.  Sadly installing the Jmouse drivers on the Green 753 didn't work so new drivers needed or just new mouse.

[granz]

... Next, thanks to Granz, I have an easy way to change colors as I want, least its easy, wish the C:\ wasn't c:\ and the color gets a tad darker but 95% happy with that...

As I mentioned on the phone, you can get the path in capital letters (in 4DOS) by using the upper case 'P' in the command: "prompt $P$g". The case of the P (for path) in the command determines the case of the path in the command prompt.

4DOS book: https://ia800103.us.archive.org/35/items/bitsavers_jpsoftware_65101374/4DOS_Reference_Manual_text.pdf page 459 of the book, which is on page 268 of the PDF file.

(This post was made as a "breadcrumb" in case you, or I or anyone else needs to find this answer again.)