Step 1: Go Get Stuff
(x1) Laser cut 1/4"-thick plywood box template**
(x1) 6V electric bell
(x1) 4 x D battery holder
(x1) Reed switch
(x1) Latching DPDT relay
(x1) Key switch
(x1) 9V battery holder
(x1) 9V battery snap
(x1) 4-40 x 1/2" wood screws
(x8) 8" zip ties
(x1) 4" x 4" x 1/8" matte white acrylic
(x1) Black and red acrylic paint
(x1) 5-minute epoxy
(x1) 30-NF Fastbond contact cement
(x1) Wood glue
(x1) Masking tape
(x1) Red and black wire
(x1) Wood stain and 220 sandpaper (optional)
(x1) Shrink tube
**The laser cut template should be etched (when appropriate) and cut. The "DO NOT INSERT AND TURN KEY" shape should be etched and cut from 1/8" acrylic.
Step 2: Epoxy
Epoxy it firmly in place.
Step 3: Mark
Next, place all of the components atop their designated spots on the bracket. The reed switch does not have a designated spot, but it should line up flush with the edge of the bracket on the side nearest the 9V battery holder.
Mark all of the component's mounting holes with pencils.
Step 4: Glue
The bracket then should be placed on top and line up to the edge of the box, such that when the box is put together the reed switch will be flush against the wall of the box.
Clamp it firmly in place and wait for it to dry.
Step 5: Drill
Step 6: Mount
Firmly mount all of the major components to the bracket with screws.
Step 7: Wire It Up
Attach another red wire to the normally open (NO) connections on both switches. Connect these two wires to the red wire from the 9V battery clip.
Attach black wires to the two normally closed (NC) connections on both switches. Connect these two wires to the black wire from the 9V battery clip.
In essence what you have just done is create a situation in which ground is always connected in the circuit. By engaging one of the switches, you are introducing a positive voltage. This - in essence - flips the polarity one way or another, and latches the relay open or closed. So, when you turn the key, it latches it closed and keeps the bell ringing. Then, when you engage the reed switch, it flips the polarity and latches it open and turns off the bell.
Before you are done, you need to wire the bell to the D battery holder and the relay.
First, wire together the black wire from the battery holder, to the frame of the bell.
Next, wire the red wire from the battery holder to the center pin on the relay.
Finally, wire the red wire from the battery holder to the coil connection on the bell. This is the mounting terminal not connected to the frame.
Cover all exposed electrical connections with shrink tube.
Step 8: Heat
Step 9: Batteries
Using 4 more zip ties, firmly band all of the batteries in place both vertically and horizontally.
Trim the excess zip tie leads.
Step 10: Glue
Hot glue the DPDT relay to the mounting bracket in the free space next to the battery.
Step 11: Clean Up
If possible, zip tie this bundle to the battery pack in order to prevent it from interfering with the bell.
Step 12: Glue It Together
Apply wood glue to all of the joints and firmly clamp it together.
Step 13: Sand
Step 14: Make the Sign
Once the sign is cut out and stenciled, paint the word "NOT" red, and all of the other words black. Paint the edge of the sign black as well.
When the paint dries, peel away the protective coating from both and pick out the island bits.
Step 15: Sand and Stain (optional)
When this is dry, lightly sand again and apply stain in the opposite direction.
Finally, lightly sand once more and lay one last coat of stain in the initial direction.
Step 16: Affix Sign
Apply contact cement to the back of the sign, and wait for this to dry as well.
Carefully align the sign with the box, as you will only get one chance to do this right, and then firmly press them together.
Step 17: Mail It to Canada
I don't know if this is on account of the long winters fostering a strong inner life and innate curiosity, or because socialized medicine makes them fearless. Or - perhaps - since everyone in the world loves Canadians, they just assume no one will send them a sealed box with a bell that will not turn off. For all I know, it could be something entirely different in the national character that causes this phenomenon. I am not really sure why they are so susceptible to inserting and turning the key.
It took Mike in Vancouver only a few minutes to insert and turn the key. I can only imagine what must have been running through his mind while he made that decision.
Remember to be a good southern neighbor and eventually tell them how to turn it off. However, I think 20 - 30 minutes is about a fair amount of time to wait before telling them about the magnet triggered reed switch on the side of the box.
Also, when triggering the reed switch, make sure the key is not inserted in lock and turned. If it is, this will not work.