Introduction: Interactive Musical Box
Here are the main building elements and tools you will need to construct the musical box:
1 wine box,
4 wood planks
4 wood blocs
2 PVC pipe
14 and 22 gauge copper wire
2 paint roller handle
10 LED s
10 resistors at 1km Ω
1 beer can
1 push button switch pack
1 battery pack which holds 3 alkaline batteries
metal spring steel strips
sheet metal screws
nuts and bolts
electrical circuit wires
hot glue gun
x acto knife
The process begins with the wine box in which we will attach wood planks with metal spring strips to the interior sides. The metal screws will be nailed to the cylinder which will be secured to the side of the box. The crank will then be attached to the cylinder from the exterior and as each user turns it, the screws will hit the metal strips and create sound. The LEDs would react and light up since the wires will be connected to a circuit that is attached.
Here is an initial proposal scheme that illustrates the main components of the musical box.
The process begins with the wine box in which we will attach wood planks with metal spring strips to the interior sides. The copper wire will be nailed to the PVC pipe which will be secured to the side of the box. The handle will then be attached to the pipe from the exterior and as each user turns it, the copper wire will hit the metal strips and create sound. The LED s would react and light up since the wires will be connected to a circuit that is attached.
Cut the wood planks diagonally so they fit within the interior of the box. Determine 5 equal spacing for holes on the wood planks (they should be a similar width to the metal spring steel). Drill the holes at 1/8" away from the edges of the planks. Cut 5 metal steel strips varying from 1 1/4" to 2" in length. Insert these strips between both wood planks where the holes are drilled and tighten temporarily with nuts and bolts. Make sure the strips are at the same level. Repeat step.
Insert the new wood planks in the box tightly and and adjust the metal strip so that they are parallel to the sides of the box. Screw the planks to the sides of the box. The second wood plank should be placed and screwed 2" away from the first one.
Draw out the metal steel strips on a piece of paper.This paper will be the musical sheet and determine the melody notes. The paper will be the template for the location of the holes drilled for the 14 gauge copper wires on the PVC pipe that will stroke the metal strips and produce sound.
Make sure that the sheet is the same diameter of the PVC pipe and that the lines match as it connects. Repeat step.
Temporarily tape the sheet to the pipe and mark out your holes for the drilling of the copper wires. The holes can be located randomly for the notes. Drill the PVC pipe and insert the 14 gauge copper wire. Connect the wire with the 22 gauge model to other one as they are conductive for the LED circuit. Repeat step for a second pipe.
With the "music sheet" template temporarily taped to the pipe, mark down random location for the holes to be drilled. Once done, cut pieces of 14 gauge copper wire to 1/4'' in length and hammer them into the PVC pipe. Wrap a 22 gauge copper wire around the bigger ones and connect all the 14 gauge copper wires together in order to ensure the conductivity of the circuit. Allow 1/4'' of spacing at the end of your pipe to wrap niobium wire around its diameter. Repeat step for the second pipe.
Cut out the rolling caps of a paint roller. Tape the caps in order to "beef" it up and make it fit within the interior of the PVC pipe. Cut the handle of the paint roller at 5" in length. Once done, mark out the hole for the handle on the box and drill the sides of it. Insert the PVC pipe with the handle. Drill and insert a "t" metal screw into the pipe and ensure that it is tighten enough to hit the new handle. Make sure the pipe's copper wires hit the metal steel strips. Repeat step for the second pipe.
Cut wood blocs to 2'' in height and nail it from the bottom in order to level and stabilize the diagonal wood planks. Loosen the nuts and bolts in order to insert the circuit wires for the LED s. Do the same step for the second pipe.
Cut a strip from a beer can at 2'' in length and 1/2'' in width. Scrape and sand it down. The strip will also serve as a conductive element for the circuit. Use a short sheet metal screw and pierce into the strip. Do this step twice.
Cut a red circuit wire in order to expose the thin steel wires. Wrap and bend it around to form an oval shape and tighten it to the metal sheet screw on the beer strip. The same should be done for the second pipe.
Measure 1/4'' over the PVC pipe and screw the newly assembled beer strip on the interior of the box at the opposite end of the handle. Make sure that the strip is in contact with the niobium wire as the pipe turns. Repeat step once more.
Use a battery pack which hold a minimum of 3 AA alkaline batteries and that has a C-Grid Molex connector. With the ends of the 2 red circuit wires (the same ones that are connected to the beer strips), attach them to the battery pack from the bottom insert "holes" and solder them together.
On the side of the box where the handles are located, center a point between both and drill a hole at 1 1/2'' from the top of the box. The size of the hole needs to accommodate a push button switch which has a contact resistance of 50mΩ (ohms). On the inner side, secure the box of the switch with a hot glue gun.
With the cover of the wine box, mark down the location of the holes in order to drill them for the LED s. Start by dividing the cover in 4 equals parts and create an "X" pattern for the lights. Space them out equally on a diagonal and drill them. Insert the LED s throughout and attach 1 km Ω resistors to the them.
This is a close up of the cover where the resistors are soldered to the LED s. The right side is marked as positive (+) and the left side is negative (-).
The cover now includes 10 LED s placed on a diagonal. With a hot glue gun, attach and glue the right side of the cover to the wine box in order to secure them to one another.
Attach and solder circuit wires to each resistors that are connected to the LED s on the cover of the box on both sides. Organize the wires by wrapping them together, as shown in the image with a yellow ban. With the niobium wire, solder all the resistors together on each side. On one end, white circuit wires should be soldered to the last resistor on each side. The other end of the wire will be soldered to the battery pack. On the same side as the beer strip, pin the circuit wires together to the side of the box as shown in the image.
Solder black circuit wires to the 2nd resistor on both sides and solder them back to the push button switch. Tie the black and white wires together so they stay organized within the box.
The box is now at its final stage. As the handles turn, the thicker copper wires hit the steel strips that are attached to the wood planks. The circuit wires that are assembled within the same planks conduct electricity to the resistors on each end of the LED s which will light simultaneously when the push button switch is turned on. The red and black circuit wires are connected to the PVC pipe and the battery pack respectively which results in a functioning musical box where 2 users are able to create sound and view illuminating lights as the cover is closed on top of the box.
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