Step 3Textile Switch Assembly
Using your template, trace an outline on the felt and cut it out. Using your layout, on the felt, draw areas where the buttons will be located.Cut out the button areas in the felt. This piece of felt will act as a spacer between the conductive fabric.
Next, cut out ten pieces (2 for each button) of corresponding conductive fabric. Then cut pieces of wire. You'll need ten, each about 6 inches long. Strip off the ends and "tin' them using a soldering iron. To connect the wire to the conductive fabric, just thread them through at the corners and glue them to the fabric using fabric glue. Repeat this for all ten wires and patches of conductive fabric.
Before gluing the conductive fabric to the felt, make a cardboard backing out of thick cardboard. Place the backing on the top case of the remote and locate some existing holes where you can thread the wire through. Choose holes that do not cross over the new button locations. I located three areas where I could thread the wire through enclosure and used a hole punch on the cardboard backing.
Now you can start gluing the conductive fabric with wires onto the felt spacer. For the top contact pads of conductive fabric push the wires through the felt spacer where the holes line up on the cardboard backing. Then glue the bottom contact pads to the felt spacer.
Glue the combo felt spacer and conductive pads to the cardboard backing.
Using the template cut out another piece of felt. Glue this piece to the top of the assembly.
Lastly, using fabric glue, cover the entire assembly with your iron-on fabric. Trim off any excess material.
For another more detailed explanation on how to make a textile switch, please visit Leah's site:
http://www.cs.colorado.edu/~buechley/diy/diy_e_sewing.html#switch
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