This should hopefully explain (almost) everything about the board design.

Building the Boards- Notes

There 3 last minute changes to the board design
  1. Main Board-- power comes in at the wrong places. Verify with a continuity tester to change the hookups
  2. Secondary Board-- two traces touch. I think I already scratched it out-- needs to be overridden with a jumper
  3. Secondary Board-- one of the big blocks by the demux'es has an extre pin included. I dremelled it out already on the built boards.

Design for computer->main board (smaller one) connector

DB 25 (Computer)

BitPinState
Bit 1XLO
Bit 2XLO
Bit 36Active HI
Bit 42Active HI
Bit 59Active HI
Bit 63Active HI
Bit 74Active HI
Bit 87Active HI
CLK5Rising Edge
DIR8HI= GND'ed, LO=Floating (1- Down/CCW 0-Up/CW)

DB 25 (Board) 

Bit	Pin	State
---------------------
Bit 1	6	LO
Bit 2	14	LO
Bit 3	16	Active HI
Bit 4	2	Active HI
Bit 5	1	Active HI
Bit 6	3	Active HI
Bit 7	4	Active HI	
Bit 8	7	Active HI
CLK	5	Rising Edge
DIR	8	HI= GND'ed, LO=Floating

This means that the DB 25 Cable is: 

Computer (Out) 	Board (In)
--------------------------
1		X
2		5
3		8
4		16
5		2
6		1
7		3
8		4
9		7
10		X
11		X
12		X
13		X
14		X
15		X
16		X
17		X
18-25		18-25, 6, 14
This is that really ugly wiring mess on the grey cable

Design for main board->secondary board connector

DB9 Main (Out) 

Pin	Meaning
---------------
1	ENABLE
2	bit 8
3	bit 6
4	bit 5
5	GND
6	DIR
7	bit 7	*****
8	bit 4
9	+9V

DB9 Secondary (In) 

Pin	Meaning
---------------
1	bit 7
2	bit 8
3	bit 6
4	bit 5
5	GND
6	DIR
7	ENABLE
8	bit 4
9	+9V

Design for RJ 11 connector 

RJ11 (Phone)

Color	Meaning
---------------
BLK	+9V
RED	CLK
GRN	GND
YLW	DIR

   +||||+		Contacts on the top, front
   |BRGY|		Clip it on the bottom
   ------
   / /\ \
  / /  \ \
 /  |  |  \ 
 B  R  G  Y
 L  E  R  L
 K  D  N  W
This is how to crimp the RJ45 connector. Hopefully this should make sense. If it's unclear, make sure it's printed in a monospaced (e.g. Courrier New) font, not a proportional one (like Times New Roman).

Connecting the RJ11 to the Drivers

Stepper Motor Drivers- MBC15161 

Pin	Input			Meaning
---------------------------------------
1	BLK			CLK + (9V)
2	RED			CLK -
3	BLK			DIR + (9V)
4	YLW			DIR -
5	X
6	GRN			GND 
7	X
8	GRN/WHT (power)		+24V
9	PPL (power)		GND

Stepper Motor Drivers- MBC158 

Pin	Input			Meaning
--------------------------------------
1	BLK			+9V
2	YLW			DIR
3	RED			CLK
4	X
5	X
6	GRN/WHT (power)		+24V
7	PPL (power), GRN	GND

How to plug in the RJ11's 

Secondary Board Layout:

24 25 26 27    16 17 18 19    08 09 10 11    00 01 02 03             
||-||-||-||----||-||-||-||----||-||-||-||----||-||-||-||---------|
|                                                                == D
|                                                                == B
|                                                                == 9
||-||-||-||----||-||-||-||----||-||-||-||----||-||-||-||---------|
30 31 28 29    22 23 20 21    14 15 12 13    06 07 04 05
Platform #1 uses motors 0-5, platform #2 uses 6-11, etc. Within each grouping, the motor assignments are: 
Connector #	Which Motor (looking from the front)
0,6,12,etc	Front Right
1,7,13,etc	Front Left
2,8,14,etc	Rear Center
3,9,15,etc	Zoom
4,10,16,etc	Lateral Motion
5,11,17,etc	Rotation

Connecting the Motors to the Drivers

Rotary 

BLK 1A (1)
ORG 1B (2)
RED 2A (3)
YLW 2B (4)
ORG/WHI + BLK/WHI - No Connection to the driver, but these two get 
shorted together
RED/WHI + YLW/WHI - No connection to the driver, but these two get 
shorted together

Linear

RED     1A (1)
RED/WHI 1B (2)
GRN     2A (3)
GRN/WHI 2B (4)
BLK - No Connection
WHI - No Connection

Calibration Notes

The software assumes all motors have the same range of movement. These figures are based on machine #1. For platform 1, it's at calibration point (1 cardboard thickness)

Movement range is: 

Motor #	Motor Position (front)	Number of turns from one extreme to the next
0	Front Right		29
1	Front Left		29
2	Rear			40
3	Zoom			14
4	Lateral			38
5	Rotation		20