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Step 2Making holes
Next i marked up twenty five spots on the foam where i wanted the leds to go. I happened to have 25 diffused red 5mm blinking leds left over from making throwies. I wish i had red/blue or reg/green flashing 5mm leds for style, but all red makes up for it in pure machismo.
I made sure to lay out the 5x5 grid pattern in no particular order because i knew id never be able to properly line everything up without measuring. And measuring was imposable since i sanded off all the straight edges. So i just picked 4 spots and eyeballed the middle points till i had 25 dots marked out.
Cheap 5mm chinese leds are just a little smaller then my cheap 13/64 drill bits from harbor freight. So i used that drill bit to bore a hole at each dot. Not wanting to put holes in my patio furniture i used an old box as a base. I tried to drill straight up and down, but some of the holes are at odd angles. Meh
Now most of the LED housing fits into the hole, but the flange at the base of the diode body keeps it from going all the way in. Using a piece of scrap foam and a 1/4 inch bit i test the depth before counter sinking all 25 holes. Id hate to ruin this one now that ive spent so much time on it.
Finding the depth acceptable i mark it with electrical tape and proceed to countersink all 25 holes so the leds just barely peek out when installed. I like the look of proper led mounts, but for projects like this the cost is just to high for that "professional" look. Check ebay for prices, in bulk good mounts are rather reasonable.
After blowing all the dust out its time for a quick test fit to make sure all the LED's seat properly; then its on to painting.
I made sure to lay out the 5x5 grid pattern in no particular order because i knew id never be able to properly line everything up without measuring. And measuring was imposable since i sanded off all the straight edges. So i just picked 4 spots and eyeballed the middle points till i had 25 dots marked out.
Cheap 5mm chinese leds are just a little smaller then my cheap 13/64 drill bits from harbor freight. So i used that drill bit to bore a hole at each dot. Not wanting to put holes in my patio furniture i used an old box as a base. I tried to drill straight up and down, but some of the holes are at odd angles. Meh
Now most of the LED housing fits into the hole, but the flange at the base of the diode body keeps it from going all the way in. Using a piece of scrap foam and a 1/4 inch bit i test the depth before counter sinking all 25 holes. Id hate to ruin this one now that ive spent so much time on it.
Finding the depth acceptable i mark it with electrical tape and proceed to countersink all 25 holes so the leds just barely peek out when installed. I like the look of proper led mounts, but for projects like this the cost is just to high for that "professional" look. Check ebay for prices, in bulk good mounts are rather reasonable.
After blowing all the dust out its time for a quick test fit to make sure all the LED's seat properly; then its on to painting.
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