Okay, this is my first instructable, but don't worry, I have been using Instructables for years. So, this project is a simple one, I am gonna show you how to make a small accent light (you can make as many as you want for bigger areas). FEAR NOT! these are not like other accent lights you have seen on Instructables, they are portable, easy to move, they are not on a strip, and they look friggin' sweet.
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Step 1: Gather Yo' Materials
IF YOU DON'T HAVE READY ACCESS TO THESE FIRST TWO THINGS, I'M TELLIN YOU RIGHT NOW, GO TO McMaster-Carr !!! You can get the other things at RadioShack Though.
-UHMW polyethylene 1.25" solid rod - 1 ft. Opaque White
-UHMW polyethylene 1.25" i.d. x 1.625" o.d tube - 1ft. Opaque White
- High or Super Bright LEDs (your choice of color, I used blue.) - 1
- CR2032 coin cell holders - 1
- CR2032 lithium coin cell battery - 1
- 1/8 watt 100 ohm resistor (you can use a higher resistance, it will just make the light dimmer) - 1
- Any size chop saw / miter saw.
- Ruler, tape measure, or combo square (to get a nice meaurement of your pieces)
- Drill press, it is reccomended that you use one for precision, but IT CAN be done with a hand drill.
- 1.25" hole / boring bit.
- Soldering Iron
- Solder (60/40 rosin core is preferable)
- 1 1/8" paddle bit
- .144" drill bit (size 27)
Step 2: Getting Started
First, You want to measure out your light body, or the tube in which the light goes. I made mine 2 1/2" long, which I think is perfect, but you are welcome to adjust that if you want. Use a pen and the tape meausure or what have you, to mark out the lenght on the tube. Cut it on the chop saw, but remember, cut on the opposite side of the piece you are going to use, to compensate for the thickness of the blade.
Step 3: Cutting the Bar Stock
Now, you want to cut off a piece of that solid UHMW bar stock that is .75 (3/4") long. Do the same thing as in the last step.
Step 4: Boring the Hole
Chances are, if you ordered your UHMW from McMaster -Carr, the solid bar does not fit into the tube. That's how mine was. If it's not, good for you, you can just skip this step. Otherwise, you want to put it in your drill press (if using a hand drill put it in a bench vise), and put that 1 1/4" hole bit into the drill chuck. Line up the bit with the top of the tube as best as you can, and then drill down appx. 3/4 of an inch. This is where that lil' bar stock piece will go later.
Step 5: Boring the Battery Holder
Now, get that 3/4" piece of bar stock you just cut, and the 1 1/8" paddle bit. Push the piece into the bottom of the tube, the side you just bored out. You might need to tap it with a hammer. When it is in, use the paddle bit and drill down about 1/2". Then, take the size 27 drill bit and put a hole straight through the middle of the piece. This is where the LED will go. You can use super glue to hold this in place if it is a little loose, but if it is really loose, you probably used too big of a bit.
Step 6: Soldering
Now, you can start puttin the electronics in. Gather yer' materials for this part, the LED, battery holder, resistor, the stuff from the list in step 1.
-Fit the LED through the hole in the bottom of light body. To keep the led in place, you can just push the leads apart.
-Now, you want to solder the resistor to the negative side of the LED, and to the negative side of the battery holder. Solder the positive lead from the LED to the positive side of the holder.
-After you're done soldering, you can just kinda push everything into the bottom, make sure none of the wires a crossing each other.
- Use epoxy, or silicone sealtant, preferably white or clear for aesthetics, to adhere the battery holder to the bottom of the body.
Step 7: Voila!
All you have to do now is (of coure after waiting for adhesive to dry), put the battery in and you've got a light!! (since there is no switch, all you have to do is take the battery out to turn it off).