Step 1: Materials and Tools Required
1. 1/4 in Plexi-glass
2. 2 in PVC cap
3. LED Light Board
4. 1/16 in plexi-glass
5. Single ply cardboard
5. Black Spray paint or paint
6. 9V Battery Connector
7. 8 feet wire (Standard red and black)
8. scotch tape
2. Xacto knife
3. Basic Tool set
4. Hot Glue gun
Step 2: Template for the Internal Design
Step 3: PVC Cap
Step 4: LED Time
1. test the LED board before securing it. connect the board to the battery case and insert the battery.
2. If you have issues with that refer to step 10 for detailed instructions on how to connect the wires to the case.
3. if all goes well the board should light up and you can proceed. If not, check connections and test again.
4. BE SURE TO REMOVE BATTERY BEFORE CONTINUING!!!
Next leave two inches of wire inside the cap and secure the board down with the hot glue.
BE SURE NOT TO TOUCH THE LED CONNECTIONS WITH THE HOT GUN BECAUSE IT COULD SHORT THE LIGHT OUT.
Step 5: More PVC
After you have secured the LED board it is time to cut the PVC pipe and secure it. you will want to obtain a 1 3/4 inch by 1/4 inch in length. try to keep it as square as possible!
Now, place it inside the cap but DO NOT SECURE IT just yet.
Step 6: Plexiglass
Depending on the intensity of your LED board you might want to add scotch tape to one side of the glass to disperse the light for better effect.
Secure the first disk with glue on both sides of the disk. This should secure the inner PVC pipe also.
Step 7: Sharps
Once you have it all cut out place it inside the cap and try to center it as much as possible. Now take the second plexiglass disk and place it on top of the template and secure it with glue.
Step 8: More Plexiglass
Step 9: Time for the Fun Part!
If you notice that there is space leftover inside the cap follow the following steps:
1. cut one more disk out of plexiglass but this time make sure the diameter is the same as the outside diameter of the cap.
2. cut out another template two onto one ply cardboard and tape it to the back of the disk you just made.
3. secure the disk with glue and make the top of the cap air tight.
Now to move on to the battery connection and testing.
Step 10: Battery Connection and Testing
Look at the back of the cap. If you see a lot of movement with the wire secure it with glue until it is immobilized. Then cut the other side of the wire to desired length. Strip a quarter inch off the end of both sets of wires (battery connector unit and the red and black wire set from the cap). Connect the wires matching the colors once again and covering up any exposed wire.
Now connect the 9 volt battery and test again.