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Remembering what I can from my old Heathkit hobbyist days, it doesn't look too difficult judging by the small of number of components. I've never made my own pc board either, but as some of the accompanying photos in the attest, it should be easy enough to jury rig a test board type setup.
I made mine based on the plans from that website. It was pretty easy to do. Cost about $8 in parts. Works fine.
One of the reasons i made one from Roli's plans rather than bought one is that I can now download dive profiles to my Palm computer. The standard Suunto interface wont work with a Palm without a lot of modification.
The roli interface is compatible with the palm serial port. You can make a few modifications so it uses less power (details are on Roli's site). I just made a special lead with a Palm connector on it. You can use the a standard hotsync cable or even the cradle but you will need a gender bender (Male to Female convertor). My interface and lead fits into a v. small waterproof box. Just plug in the Palm and the Suunto and press a button.
Making it compatible with the Suunto Dive Manager is a good idea. I think it would be a bit tricky but I shall have a look this weekend.
I hit the local Radio Shack to start collecting the bits needed to construct the interface. That evening while surfing I found DiveInn.com in Spain (don't know how I've missed it before) who was offering the interface for US$87 shipped. This is about the same price as Simply Scuba, but shipping was only US$9 versus the US$20+ they wanted from Simply Scuba. And this is much cheaper than anyone in North America was selling it for - even on ebay where they been going for US$100-110 of late.
So I ordered it. They say 4 day shipping which will get it here by Saturday - we'll see.
Anyone want to buy a handful of transistors and resistors?