My original instructable had a couple of flaws, some of them very important. I was originally going to post the updates on my first instructable, but there were so many changes that I had to make a whole new one.
Among these changes are:
- Overcharge protection (the main reason I wrote a new Instructable)
- Only one wire connecting the top to the bottom, not two little annoying ones
- No wires around the edges
- No annoying diodes where your hand goes
- You can get the stylus out now (I accidentally put a solar cell over it the first time, silly me)
This is my third Instructable, and if you have any questions, don't hesitate to post a comment! Don't forget to rate and vote either!
Step 1: Materials
- Four (4) 60 x 60 mm solar cells http://www.allelectronics.com/make-a-store/item/SPL-61/SOLAR-CELL-60MM-X-60MM-X2MM/-/1.html
- Two (2) diodes, almost any kind should work http://www.allelectronics.com/make-a-store/item/1N4001/RECT-DIODE-1AMP/50PIV/-/1.html
- One (1) Overcharge protection chip http://www.batteryjunction.com/prcimopfor3l.html
- Some thin wire (preferably at least two colors)
- Scotch tape
- Electrical tape
- 4.2 cm long piece of thin heat-shrink tubing
- Some ribbon
- Nintendo DS lite (really?)
- Hot glue gun with glue
- Soldering iron with solder
- Wire cutter/stripper
- Helping hands tool (not required, but helpful)
- Solder Sucker (helpful if you mess up)
- Small phillips screwdriver
Step 2: Make the Panels
After you made one panel, use the other two cells to make another.
Step 3: Wiring Part 1
Step 4: The Top Diode
Step 5: Wiring Part 2
Step 6: Heat-Shrink Tubing
Step 7: Join the Panels
Step 8: Add the Overcharge Protection
Step 9: Bottom Panel Negative
Step 10: Bottom Panel Positive
Hooray! You completed the panel assembly!
Step 11: Prepare the Battery
You guys are going to kill me in the comments for soldering directly to the battery, I just know it. But there was no other obvious way to do it, and it had to be done.
Repeat this with the other wire and the other battery terminal. Cover the terminals with a piece of electrical tape. Test your wiring with a multimeter by connecting it to the wires from the battery. DO NOT LET SOLDER SHORT OUT THE TERMINALS OR ALLOW THE WIRE ENDS TO TOUCH, THE BATTERY COULD EXPLODE!!!!!!
Step 12: Prepare the DS
In the slot where the battery was, you should see two terminals. Wedge one end of one of the wires into one of the terminals and use the helping hands tool to hold it in place. Solder the wire there using only a small amount of solder. Repeat this with the other wire and the other terminal.
Place a strip of ribbon into the battery cavity so that the ends come out of both sides. Because we added some stuff to the terminals of the battery and the DS, it is very cramped in there and the battery has to be forced in. The ribbon is very important and it is near impossible to get the battery out without it.
Step 13: Prepare the Battery Cover
Do this outside because it creates lots of tiny plastic particles that float in the air and probably isn't the best thing for your lungs.
After that is over, screw the battery cover back on the DS. The four wires should fit nicely through the groove you created. Put a piece of electrical tape over it to hold the wires in place. Put a piece of tape over one of the wires from the battery to keep it from shorting.
It is also a good Idea to turn on the DS at this point in time. If it doesn't turn on, you're doing good! If it does turn on, you probably forgot to cover the battery terminals. Do that now if you have'nt.
Step 14: Unite the Panels and DS Together!
Take the positve battery wire (the red one near the top of the battery compartment) and solder it to B+ on the chip. It should be the only wire on that terminal. Now, before you solder the negative battery wire, test it with a multimeter to make sure there are no shorts. Set the multimeter to measure current, touch the positve terminal to B- on the chip, and touch the negative terminal to the negative battery wire. I got about .01 ma, because the DS uses a small amount of power in standby. Now do the same thing with the voltage setting, and you should get about 3 volts. This means that power is ready to flow through the DS. If either of your readings are way off, check your wiring. If you got them, proceed.
Take the negative battery wire and solder it to B- on the chip. It should be the only wire soldered to that terminal.
You are now ready to test it!
Step 15: Test the Setup
You can now proceed to attaching the panels to the DS.
Step 16: Attach the Panels
Once you have the bottom panel attached (see second picture), fold the top panel onto the top of the DS (see third picture). Use the same glueing method as with the bottom panel.
Tip: press hard while the glue is drying so the panels don't stick out as much.
NOW IT"S FINISHED!
Step 17: Option 2
This switch changes between charging the battery from the solar cells and transferring the charge to the DS.
Step 18: Enjoy not Using the Charger!
Whenever I am not using the DS and it is sunny outside, I set the DS in the sun to charge. I never leave it outside, I just set it by a sunny window or on the floor. Unlike my previous instructable, it doesn't mattery how long you leave it in the sun because the chip protects the battery. The solar panels are made for charging the battery, so don't get the idea that you have to hold this in the sun to play it. Also, the way I did this still works with the charger,
Ever since I did this, my DS never needed to use the charger. It works excellently and looks cool too. It has a much sleeker design than my previous solar DS and the protection circuit saves the battery. Not only is this good for the environment, but you will never have to worry about bringing the DS charger with you again!
By the way, do not let the security people see this in an airport. You have been warned.
Here are some pictures of it charging. It is propped up on the stylus to get as much sun as possible.
Thanks for viewing, and don't forget to rate! I hope you try my project, please send me pictures if you do this! If you have a question, don't hesitate to ask, I will gladly answer it!