Step 1: Gather Your Tools and Supplies
1: transparent or translucent vinyl tubing (I used 1/4 inch ID, about the minimum size I could work with)
2: several 3mm 4Volt ultra bright LED (Larger size LED will need a larger diameter tubing)
3: electrician's fish tape or long stiff wire (needed during assembly)
4: fine gauge speaker wire ( I used 26AWG wire)
5: Ultra sharp push pin (an awl or needle will also work)
6: firm stable work surface
7: small ruler
8: sharpie pen
9: hot glue gun
10: inexpensive flashlight
11: small flush cut side cutters
Step 2: Prepare Your LEDs
It is best to stagger the cut leads both for easy identification and for easier insertion into the wire.
Step 3: Prepare the Wire
The wire is marked at regular intervals with the sharpie.
The first LED is inserted into the end of the speaker wire. I chose this type of wire for two reasons. The first is that it has a clear casing which transmits some of the light to the opposite side that the LED is mounted on. And the second is that the wire consists of two separate colours, One silver and the other gold.
The LED has a flat mark around the lower rim which identifies the cathode (negative side) coincidentally I prepared my LEDs with the shorter lead identifying the cathode as it did from the factory.
I chose the mantra short to silver when I assembled the string. You carefully and a straight as possible push the sharpened LED leads into the exposed wire at the end.
Step 4: Insert LEDs Into the Wire.
Once you make one set of holes you will have to insert the LED. The holes will tend to close up making the insertion harder if you wait.
Firmly push the LED leads into the small holes and along the wire core. You will only be able get them in about 1/8 to 1/4 of an inch before the leads bend. This is sufficient for good contact.
You will have to repeat this procedure until all of the LEDs are placed...
Step 5: Disassemble the Flashlight and Test the String.
You will have to disassemble the head of the flashlight
With my flashlight:
unscrew the lens cap and lens cap cover.
You will be left with a lower case, battery carrier, batteries and on/off switch.
The cathode is connected to the case by stripping off some of the silver wire coating and wedging the bare wire between the base and lens cap cover.
The light circuit board has a wire protruding from it, you will have to remove it if you do not want the flashlight to light up. I removed it...
Press the power button. If your LEDs do not light then reverse the leads. If any individual LEDs do not light either insert them farther of reverse them.
Once you are satisfied with the string turn it off.
The gold coloured wire is stripped bare and wrapped around the spring which attaches tot he anode. The lens cap is then reassembled minus the lens to allow the wire to pass through.
Step 6: Secure the LEDs and Feed the Tube
The glue will keep the LEDs from coming out of the wire. Do Not skip this step...
The cooled off glued string has to be pulled into the tubing either by a long stiff wire or electrician's fish tape as shown. The wire will tend to stick to the vinyl tubing so you will have to use a little patience and wiggle the wire and tube so that the wire pulls freely. Do not fore it otherwise the LEDs could be damaged or the wire could break. It is not advisable to the some sort of lubricant as it will not look good when it is turned on.
Once the wire is pulled though, the ends are sealed with a liberal amount of hot glue. The LED end has to be glued all the way past the led to the wire otherwise the led could pull out of the wire. stick the nozzle of the glue gun all the way in and back it out gently to achieve a flush glue seal.
Step 7: ENJOY
All told mine cost me less than $7...