Jolly Chimp(s) Doorbell

This Instructable is how I made a novelty doorbell utilizing 2 classic Jolly Chimp toys. The projects core electronic platform can be used to operate just about any battery operated item, or items, within reason. I used these classic toys but the electronics can be altered as necessary. Step six is the magic step that really gave me the results I wanted, skip the stupid shelf instructions if you want, skim the mounting, wiring and voltage parts, but step six, in my opinion, is what made the whole project awesome. Take a moment to read it, it's the kind of extra bit that once you appreciate it... you'll find all kinds of other things you can use this extra bit for...

I also made a shelf for them to sit on and have included some of the basics regarding that portion of the project too.

Supplies

Supplies for the shelf:

1" X 4" X 8' pine lumber

2'X 2' X 1/8" plywood

wood putty

spray primer paint

spray paint in the color and sheen of your preference

Zip ties

4" metal "T" brackets

Tools:

Nail gun & nails

Jigsaw

Router and rabbeting bit

Orbital sander and sanding discs

Keyhole router bit

Supplies for the electronics:

2 Jolly Chimp toys (or some other electronic item with a physical on/off switch)

2 LM317 modules or one for every device you'll be powering Amazon.com: LM317 Adjustable Voltage Regulator Power Board DC-DC Converter Step-Down Module Adjustable Linear Regulator Power Supply, Pack of 10 : Automotive

12 volt ac to dc power supply (the transformer that is already installed in most houses may be adequate and this may not be needed).

Solid core wire

1 DC 5 volt trigger time delay switch relay module Amazon.com: DC 12V Timer Module,Adjustable Timer Delay Turn Off Module Timing Relay Time Switch 1~10sec : Tools & Home Improvement This item is the heart of how this project works without involving a microcontroller.

Step 1: Building the Shelf

I didn't want my "chimps" sitting on just any shelf. The existing wiring in my house emerge from a hole in the wall in an entryway. I had already decorated with some secret society/Masonic themed items, so I decided to tie the chimps in with that stuff by making a shelf that is accented with some imagery common amongst those societies. I also added fez hats which tied everything together.

Since the imagery I am using is triangular. I made a triangular shelf to match.

Each board is cut to a length of 21" on a miter saw set at a 30 degree angle on both ends with the end of each board making one of each of the three corners of the triangle and it is overlapped on the opposite end. I did a practice run to check my angles with some scrap wood.

If you plan ahead (I didn't), use the rabbeting bit to cut a groove along the shortest side of one edge of the boards.

Once you've confirmed that the angles line up correctly and make a proper equilateral triangle, use a nail gun to attach the overlapping board to the corner board on all three corners.

Now that we have a solid triangular frame utilize the rabbeting router bit to cut a groove on the back side of the triangle. Since the router bit won't be able to go all the way to the corner, use a chisel to remove the remaining wood.

Measure the space inside the rabbetted groove of the triangle and transfer your measurements to the plywood and cut out the triangle using the jigsaw. The plywood triangle should fit neatly in the groove of the triangle frame. Tack this in place with the nail gun.

Fill all the nail holes with wood putty and any cracks, knots, or defects.

Sand to your satisfaction starting with coarse to progressively finer sandpaper with the orbital sander.

I didn't really want the shelf to look too much like your average wood shelf so I applied a generous coat of sandable primer and repeated the sanding process using finer sandpaper each cycle until the smoothness is to your satisfaction.

Apply the final coat with the colored paint of your choice, lots of thin coats should give the best results and keep the paint from running.

I repeated the whole process with my emblem but I skipped the primer application, because mdf, which is the material the emblem is laser cut into, is already very smooth and primer didn't seem to enhance anything. I just spray painted it without the primer coat.

I used scrap wood and cut out blocks to give my artwork some depth.

Step 2: Assessing Devices for This Project

One important detail for this project to work is that each device needs a physical on/off switch not a digital button. The simplest way to explain this is if the switch is left on, your device would eventually wear out the batteries. We don't need to worry about dead batteries since this will be wired to a low power transformer with continuous power. Our device will only run when the doorbell button is pressed. Low power for only a short duration, not too taxing for a battery powered device

Step 3: Preparing the Chimps for Mounting

The toys require 2 "D" cell batteries @ 1.5 volts each or a total of 3 volts. Use a multimeter to check the output of the power supply you are using. In this case, since I'm providing power to 2 devices needing 3 volts each the power supply needed would have to be at least 6 volts. In my experience, it's usually wise to have a power supply that is a little more than your devices say they require.

Temporarily connect one of the LM317 modules to your power supply and measure the output. Adjust the multi turn screw on the potentiometer until the power output matches the voltage requirements on your device. in this case 3 volts. Temporarily attach, via alligator clips, the positive output and the negative output from the module to your device and confirm that your device powers on and operates as expected. If you're powering more than one device do the same steps for each one and then connect them all together to confirm you have enough power for everything.

One you've confirmed that everything plays nicely together make your connections permanent. I did so by soldering directly to the springs inside the chimps. You may need to get creative with your contacts if you don't want to permanently solder to your device. Since the area for the batteries in these is pretty big, I was able to hot glue the modules inside the battery box for each and left the positive and negative wires protruding, these will attach to the wires coming out of the wall from the doorbell button.

Step 4: Brackets for the Chimps

I opted to avoid using any permanent fasteners to affix the chimps because they are arguably antiques so my solution in this case was to fasten 2 - 4" "T" brackets to the top edge of the back of the shelf. I then used zip ties to fasten the chimps to the shelf. From the perspective of a person standing looking up at them, the zip ties are hardly noticeable and my Jolly Chimps still maintain their integrity as antiques. Route the wires so that they are able to be attached together to both the positive and negative wires coming out of the wall. Once the wires are satisfactorily placed and each device is situated the way you want, Affix your devices to the shelf. In this case I used zip ties and ran each one through one of the holes in the "T" brackets to keep them from shifting.

Step 5: Integrating With Home Wiring

What inspired this idea was that my original doorbell transformer quit working and through the process it dawned on me that if I planned things out I could wire just about anything I wanted to the already existing wires provided that I only use low power that the wire is rated for. I replaced my transformer with a 12 Volt AC to DC power supply but the project could have been powered by the existing doorbell transformer or even a spare wall wort.

If you intend to use an existing doorbell transformer check the voltage coming from the wires coming out of the wall, you'll need to get someone to press your doorbell button while doing this. Mine was bad so I used the power supply listed in the supply list.

At this point you can mount your shelf and attach your wires and if you've done a careful job of following all the steps your devices should come to life when the doorbell is pressed.

Step 6: Magical Time Delay Relay

So, after wiring it all up and pressing the button it worked, but not in the way I wanted... In order for my chimps to do their thing the doorbell button has to be depressed, and no-one uses a doorbell that way. They just press it once briefly and wait for someone to come to the door. This was a less than impressive performance. The magical solution to this is to wire in a time delay relay module. The module functions by a potentiometer that you adjust that affects how long the relay stays closed. Connect the doorbell wires in place of the push button (or trigger as some of them are labeled), cut the supply voltage wire to your device and connect each wire across the common and N.O. (normally open) side of the relay, connect the positive and negative voltage wires from the power supply to the V+ and V- terminals and connect the ground connections together. I also added a diode to prevent any voltage to kick back into the circuit. Adjust the potentiometer to the duration you'd like your "doorbell" to be activated, it requires quite a few turns to see any difference but there's an indicator light and an audible click each time the trigger is engaged, which helps with adjusting. I set mine at about 4 seconds but it's probably a little too long if you ask my housemates...