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Step 3Make the New Polycarbonate LED Housing
The new housing is made of scrap polycarbonate. It doesn't take much. The thicker piece will be the back, and the thinner will be the front. One of the housings is different, because there is space for the power/mode switch, which controls both lights.
1. Cut one set of matching rectangles out of the two different polycarbonate thicknesses. Thes rectangles should be about 0.2 inches wider then the PCB on all sides. Mine measures 0.75in by 2.5in.
2. Use a dremel tool to carve out the thicker block such that the PCB with the wires behind it will comfortably fit inside.
3. Drill 5 LED diameter holes in the thinner polycarbonate. Make sure that these holes properly line up with the LEDs and that the cases line up when assembled.
4. The other housing needs to be made longer (2.75 in) for the switch cutout. I used an smt click switch.
1. Cut one set of matching rectangles out of the two different polycarbonate thicknesses. Thes rectangles should be about 0.2 inches wider then the PCB on all sides. Mine measures 0.75in by 2.5in.
2. Use a dremel tool to carve out the thicker block such that the PCB with the wires behind it will comfortably fit inside.
3. Drill 5 LED diameter holes in the thinner polycarbonate. Make sure that these holes properly line up with the LEDs and that the cases line up when assembled.
4. The other housing needs to be made longer (2.75 in) for the switch cutout. I used an smt click switch.
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