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Step 6Cylinder
Attaching the drive shaft bearing ....
1. From sheet aluminum, cut a round disk sized to fit down inside the glass cylinder, almost all the way to the bottom (that is the closed end of the cylinder).
Since the glass cylinder inside is tapered, I used manila file folder material to cut test pieces until I got a good fit between the cylinder wall and the disk - then I cut the real one out of aluminum.
2. Make a hole in the center of the aluminum disk for the nylon flange bushing. Attach the bushing with hot melt glue or a small piece of tubing pressed onto the back of the flanged bushing.
3. To space the disk/bushing assy out from the bottom face of the glass cylinder cut 3 slightly smaller disks from cardboard and glue them together to form one thick stack. Cut a large opening in the center to provide clearance for the bushing.
4. Apply double stick tape to both sides of the cardboard disk pack. Attach the disk pack to the bottom of the cylinder, and then attach the disk/bushing assembly to the other side of the cardboard pack. It's important to assure the bushing ends up centered within the cylinder
Adding aluminum top and bottom bands ...
5. Apply double stick foam tape to the outside top and bottom portions of the glass cylinder.
6. Cover the outside end of the cylinder bottom (closed end) with a couple of strips of aluminum tape. (see photo)
7. Top Band Instructions - The "top band" attaches to the closed end of the cylinder (normally the bottom of the cylinder.) Cut a 22 mm wide band of aluminum strip long enough to wrap completely around the top band of double stick tape - cut it a little on the long side so there is about 1/2 inch of overlap that you can tape down with aluminum tape.
8. Bottom Band Instructions - If you're going to use the Simple Controller the bottom band is just the same as the top band.
Special Instruction for the Full Function Controller (Touch Sensor). The bottom band is actually the "touch activation" sensor. This means you need to attach a wire to the aluminum band which will be routed thru a hole in the base plate to the controller board.
Cut the band extra long so that you can cut a taper it at one end. Sand down the inside aluminum band surface to provide good electrical contact and then "roll and crimp" one end of 12 inch long length of stranded wire to the band end (see photo). Cut a 1/2 " gap in the double stick tape to create a pocket for the crimp/wire to "fall" into.
Finally, attach the band to cylinder using the double stick just as you did with the top band and tape the overlap down with aluminum tape.
To the other end of the sensor wire solder a one pin male header (see photo).
1. From sheet aluminum, cut a round disk sized to fit down inside the glass cylinder, almost all the way to the bottom (that is the closed end of the cylinder).
Since the glass cylinder inside is tapered, I used manila file folder material to cut test pieces until I got a good fit between the cylinder wall and the disk - then I cut the real one out of aluminum.
2. Make a hole in the center of the aluminum disk for the nylon flange bushing. Attach the bushing with hot melt glue or a small piece of tubing pressed onto the back of the flanged bushing.
3. To space the disk/bushing assy out from the bottom face of the glass cylinder cut 3 slightly smaller disks from cardboard and glue them together to form one thick stack. Cut a large opening in the center to provide clearance for the bushing.
4. Apply double stick tape to both sides of the cardboard disk pack. Attach the disk pack to the bottom of the cylinder, and then attach the disk/bushing assembly to the other side of the cardboard pack. It's important to assure the bushing ends up centered within the cylinder
Adding aluminum top and bottom bands ...
5. Apply double stick foam tape to the outside top and bottom portions of the glass cylinder.
6. Cover the outside end of the cylinder bottom (closed end) with a couple of strips of aluminum tape. (see photo)
7. Top Band Instructions - The "top band" attaches to the closed end of the cylinder (normally the bottom of the cylinder.) Cut a 22 mm wide band of aluminum strip long enough to wrap completely around the top band of double stick tape - cut it a little on the long side so there is about 1/2 inch of overlap that you can tape down with aluminum tape.
8. Bottom Band Instructions - If you're going to use the Simple Controller the bottom band is just the same as the top band.
Special Instruction for the Full Function Controller (Touch Sensor). The bottom band is actually the "touch activation" sensor. This means you need to attach a wire to the aluminum band which will be routed thru a hole in the base plate to the controller board.
Cut the band extra long so that you can cut a taper it at one end. Sand down the inside aluminum band surface to provide good electrical contact and then "roll and crimp" one end of 12 inch long length of stranded wire to the band end (see photo). Cut a 1/2 " gap in the double stick tape to create a pocket for the crimp/wire to "fall" into.
Finally, attach the band to cylinder using the double stick just as you did with the top band and tape the overlap down with aluminum tape.
To the other end of the sensor wire solder a one pin male header (see photo).
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