This project is aimed at every pious 3D printer out there although being a believer is not mandatory.
This little cross is very easy to make required that you have a 3d printer or know someone who can print the parts for you. I printed the parts on a xyz Da Vinci 1,0 which has a build area of 20x20x20 cm. The total used area is 150 x 180 with a bit of margin to spare so smaller printers should be fine printing at 100 % scale. There should be no problem dividing the model into smaller parts in order to print the cross in a smaller printers or why not just scale it down.
Step 1: Tools and Materials
Provided that you have a printer or the printed parts all you'll need are some basic tools.
- Garden light
- Soldering iron
- Glue gun
- exacto knife
- Screw driver
- marker (cd pen)
If you don't have a soldering iron or a glue fun you can still improvise. You can just peel back the wires and twist them around each other to make a connection and then use electrical tape to re-insulate them. As for the glue gun you can use acetone (nail polish remover) to make the printed parts bond together.
Get the files here:http://www.thingiverse.com/thing:766990
If you don't know anyone who can print this for you here's my hub: https://www.3dhubs.com/stockholm/hubs/cordova
Step 2: Start by Gutting the Garden Light
Start by removing the foot and the screws until you are left with the just the electronics.
Mine had 3 small screws but the designs of these little lights can vary a lot.
Using your pliers break open all the plastic housing taking care not to crack the glass on the solar panels. Once you have it detached you can mark one of the wires so you know where to reattach it. Heat up your soldering iron and un-solder both wires. Pull everything free of the plastic housing and re-solder the wires in place.
Optional: If you don't have access to a soldering iron you can just cut the wires, peel back the rubber insulation and then twist them around each other and use tape to re-insulate them.
Step 3: Assembling the Electronics
In this step you will assemble the batter case.
Simply squeeze the connectors into the case with either your fingers or pliers.
Make sure they sit snug in the in there and they bend part of the connectors that stick out on the sides.
Once both connectors or in place, put the battery in and close the case with the lid. The lid stays there by friction alone.
Don't worry if yours doesn't shine like in the picture. It can be that the battery isn't charged or it's too light where you are. This little things only light up when the solar panels drops below a certain voltage. Try covering the solar cell with your hand to prevent light from reaching it. If it still doesn't light up you can leave to charge for a moment and then try again. Provided that your wires are well connected it should light up.
Step 4: Putting It All Together
Now its time to fire up the glue gun.
1. Push in the heart into the cross and then 2. turn it around. 3. Fit the led into the hole in the heart.
4. Then dab a bit of hot glue over the backside of the heart and in the, rectangular inset and fit the solar cell over the heart and the battery case in the inset bellow. While your at it you can add a little hot to the foot of the cross and leave it to set for a few minutes.
Your all done and all you need to do is stand it on your window where the light can shine on the back of it and enjoy the cozy decorative light in the evenings when the light comes on.