Step 1: Ingredients
• thin plywood
• 1 straw
• paper adhesive tape
• wood glue
• transparent sandable epoxy resin for plastic
• punctured bicycle inner tube
• sandpapers with different grades
• and of course your favourite flash light
Step 2: Print Flashlight Head's Profile
Step 3: Creating Profile Shapes
Step 4: Create 2 Structre
Step 5: Finish These 2 Structures
Step 6: Cut All Optical Fibers to Size
Put a tape on one ending to close, than you can start to put small amount of optical fibers into it, than cut to size. In this way you won't have to sand a lot.
Step 7: Bundle Toghether the Optical Fibers (hardest Part)
Start to put optical fibers in it.
Note: these fibers are very delicate to handle, specially at the end of this process. If you bend them to hard, than won't be straight anymore and you have to change them.
Step 8: Gluing Fibers Together With Resin
Mix together the two compound epoxy resin and start to dip fibers into mixture. You have to be very fast, because glue sets in 5 minutes. Use gloves and prepare paper towel in case there will be spilling.
When you are ready you hold well the unglued part and start to push down the lower structure till you arrive at the top of the bunch. This is not easy because the fibers together with the glue becomes very thick. It was good that there was space enough for glue.
Step 9: Sanding
Step 10: Gluing Velcro
Cut from tire tube a stripe with the width of the velcro than put/measure around the circumference of the flash light and cut to size. Cut another stripe of velcro, aprox. 3 cm/1.18 inch bigger than rubber and sew them together. (velcro's fluffy side facing outwardly)
Step 11: Mount Optical Fiber to Flashgun
Step 12: Images
I made this flashlight extension 2 years ago, just didn't have time to play with it, so these images are more just a play. This needs more development to make it work. I think it could be more useful as accent light in object, insect photography.