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Step 5Grind the LEDs
Since I used 2.5mm thick polycarbonate sheets, I had to grind the LEDs flat on both sides for a flush fit.
I used a belt sander to do this (attached to my band saw), and it went really fast. Simply sand down the sides of the LEDs until they resemble tiny tombstones. Don't take off too much plastic though, just enough so that the LED is the same thickness as the plastic.
If you're using 3mm LEDs you may not have to remove any material at all. Similarly, if you used thicker plastic then you won't have to sand the LEDs as thin.
Do 28 white LEDs (did I mention how handy a belt sander is?) and 14 red LEDs (it's really handy!)
I used a belt sander to do this (attached to my band saw), and it went really fast. Simply sand down the sides of the LEDs until they resemble tiny tombstones. Don't take off too much plastic though, just enough so that the LED is the same thickness as the plastic.
If you're using 3mm LEDs you may not have to remove any material at all. Similarly, if you used thicker plastic then you won't have to sand the LEDs as thin.
Do 28 white LEDs (did I mention how handy a belt sander is?) and 14 red LEDs (it's really handy!)
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