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Step 18Build the cube: create a jig
In order to make a nice looking LED cube, it is important that it is completely symmetrical, that the space between each LED is identical, and that each LED points the same way. The easiest way to accomplish this is to create a temporary soldering jig/template.
1)
Find a piece of wood or plastic that is larger than the size of your cube.
2)
Find a drill bit that makes a hole that fits a LED snugly in place. You don't want it to be to tight, as that would make it difficult to remove the soldered layer from the jig without bending it. If the holes are too big, some of the LEDs might come out crooked.
3)
Use a ruler and an angle iron to draw up a grid of 8 by 8 lines intersecting at 64 points, using the LED spacing determined in a previous step.
4)
Use a sharp pointy object to make indentions at each intersection. These indentions will prevent the drill from sliding sideways when you start drilling.
5)
Drill out all the holes.
6)
Take an LED and try every hole for size. If the hole is too snug, carefully drill it again until the LED fits snugly and can be pulled out without much resistance.
7)
Somewhere near the middle of one of the sides, draw a small mark or arrow. A steel wire will be soldered in here in every layer to give the cube some extra stiffening.
1)
Find a piece of wood or plastic that is larger than the size of your cube.
2)
Find a drill bit that makes a hole that fits a LED snugly in place. You don't want it to be to tight, as that would make it difficult to remove the soldered layer from the jig without bending it. If the holes are too big, some of the LEDs might come out crooked.
3)
Use a ruler and an angle iron to draw up a grid of 8 by 8 lines intersecting at 64 points, using the LED spacing determined in a previous step.
4)
Use a sharp pointy object to make indentions at each intersection. These indentions will prevent the drill from sliding sideways when you start drilling.
5)
Drill out all the holes.
6)
Take an LED and try every hole for size. If the hole is too snug, carefully drill it again until the LED fits snugly and can be pulled out without much resistance.
7)
Somewhere near the middle of one of the sides, draw a small mark or arrow. A steel wire will be soldered in here in every layer to give the cube some extra stiffening.
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Hey guys I finished my milling and I wanted to point out 2 very big mistakes for milling if anyone else is going to do this. The first mistake was that I didn't drill all the way through the board. Pretty obvious, but very essential because when I was done with the layers i was going to solder them together and flip it upside down so the leads are going through the holes. Second big mistake: As you can see, the left milling has drill traces between the holes. I thought it would be a good idea, but it prevents the LED's from fully going in the holes and they pop out really easily.