How to make a Heating and Cooling Jacket

Step 12 Assembling Your Fan "Sandwiches"

 

        First, you will need to prepare the fans for the jacket before they can be sewn in. To do this, the felt, supports, mesh, and fans must all be assembled together. 

1.       Trace and cut out one large circle, with a diameter as close as possible to that of the fan’s, on each of the felt squares.

2.       Sew on a mesh square to cover each of the felt circles using regular sewing thread. Trim excess mesh around the circle after sewing. Be careful not to cut the mesh too close to the thread, however, because the mesh can come apart easily. Leave a gap of about one centimeter between the thread and the edge of the mesh all the way around the circle.

3.       Optional: If your fans only have support on one side, you will need to create a frame for the fans. This will not allow any interference with the blades so that the work properly. You can make some type of frame from wood or plastic that matches the border of the fan. Also, cut holes at each corner to match up with the holes in the fan corners that were meant for screws. (*see photos)

4.       Piece together the sandwiches, with one felt square on each side of the fan, and a support ring between fans and felt if necessary. Orient the felt squares so that the side with the extra mesh faces inward. 

5.       Using Gorilla Glue or similar product, glue the pieces together. MAKE SURE NOT TO GET ANY GLUE IN THE WAY OF THE FANS!!! This will prevent them from spinning and will be difficult to fix. Also, try not to get glue over the screw holes. This way you can sew through them later.

6.       After glue has dried, trim the felt squares around the edges. Make sure to leave about one to two centimeters of felt all the way around in order to sew to the jacket. 

7.       Sew the sandwiches together to reinforce the glue. Using regular thread, sew through all materials where the screw holes are in the corners. Also, in the middle of each side, sew a few strands of thread between the two felt squares in order to help keep the middle areas together. The thread will show on the outside of the fan casing. See photo for a better idea of what this looks like. 

8.       Stick the loop Velcro onto one side of each of the fans, covering the surface of all of the felt. You should reinforce them with super glue or sewing, so the Velcro will not peel off. Make sure that, on two of the fans, the Velcro is on the side that blows air out, and on the other two it is on the side that does not blow air out, rather pulls air in.