In this instructable / video I am going to show you step by step how to make creative and unique looking wall clock with integrated motion lighting system.
This quite unique clock design idea is orientated to make clock more interactive. When I walk by the clock, I always raise my hand to activate its lighting! It maybe sounds silly, but every time I do that, I feel somehow very satisfied! :)
But if you don't want this motion lighting system you can just make the clock without it, because even without the lighting, this clock looks really cool!
TOOLS YOU'LL NEED:
- Jigsaw (amazon.com or local hardware store)
- Jigsaw blade http://a.co/f2e1zEl (T-Shank)
- Router http://a.co/1oW9oWv
- Drill http://a.co/izSs6RZ
- Hair dryer (amazon.com or anywhere)
- Clamps http://a.co/9MF1qcv
- Speed Square http://a.co/8UTloCA
- Fretsaw http://a.co/5eUmLZx
- Sandpaper 120 grit (amazon.com or local hardware store)
- Sandpaper 220 grit (amazon.com or local hardware store)
- Soldering iron kit http://a.co/3rbGnHG
- Curved pliers (amazon.com or local hardware store)
- Cutting plier (amazon.com or local hardware store)
- Small utility knife http://a.co/5hWZwkO
- Hot glue gun http://a.co/cWdXE8P
MATERIALS YOU'LL NEED:
- Wood board MIN 21x21cm and 1.8cm thickness (local hardware store)
- Wood finish (local hardware store)
- Plywood (local hardware store)
- Wood glue http://a.co/46WKSdw
- Super glue http://a.co/9M9bUIL
- Clock Mechanism http://a.co/gR7cQ6w
- 1x AA Battery (local hardware store)
- NPN Transistor http://a.co/dSXFwF9
- IP20 RGBW LED strip http://a.co/eynIchO
- 2x 18650 3000+ mAh protected Li-Ion batteries http://a.co/iwt3khT
- DIY battery box http://a.co/0iidGwE
- HC-SR501 Motion sensor http://a.co/d6d3BNa
- Wires (local hardware store)
- Electrical tape (local hardware store)
Templates and Circuit:
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Step 1: Preview of the Finished Clock
Some different angles of the finished wall clock.
Step 2: Power Consumption
Total power consumption when clock's lighting is on - 30.2 mAh.
Powered by two Li-Ion 18650 batteries in series giving 8.4V (max charge).
Although RGBW LED strip needs 12V, with 8.4V (or even with 6.4V, when I tested)
Red channel glows very bright compared to regular white color LEDs. So single Red color is quite good solution for simple lower voltage lighting.
Step 3: Starting Point
Glue my made template (210x210mm) on 18mm thick wood board and drill 11mm depth hole for the router bit to fit in.
Step 4: Routing Spots for the Electronic Items
Route all spots for the electronic parts with depth as written on the template.
Step 5: Cutting Cubes
Now we can start cutting all "exploded" parts. Not all parts can be cut with a jigsaw, so for those use fretsaw.
Step 6: Sanding All Pieces
Sand all cut pieces with 120 and 220 grit sandpapers.
Step 7: Drilling Holes
Drill holes for the clock mechanism and for the HC-SR501 motion sensor. For the sensor, drill hole size as sensor itself and then drill thinner hole, that the sensor would trigger at more direct and narrower angle.
Step 8: Starting Gluing Cubes
Place something beneath the main part of the clock and start gluing small cubes. Use my made "exploded" clock template to know where to glue and mark off cubes one by one on the template when you glued it.
Step 9: Marking Spots for the Leds
When all glued parts dried up, cut 50 cm of unprotected RGBW LED strip and mark spots around the clock's back where you'll need to glue small blocks for the RGB LEDs. Usually white LEDs on a strip are RGB and yellow ones emits white color (which we won't be using), but check your strip to make sure.
Step 10: Cutting and Gluing Small Blocks for the Leds
Glue my template and cut small blocks. Sand them and glue on the marked spots around the back of the clock.
Step 11: Applying Finish
Apply any finish you like. I applied one coat of white color paint. It is good idea to paint back of the clock with bright color for better light reflection from the LEDs.
Step 12: Circuit of This Build
Circuit of this build for who knows what their are doing.
Step 13: Start of Step by Step Soldering of the Electronic Components
Solder one side contacts of the DIY 18650 battery box with a short wire. In other side solder two ~15cm long wires and bent connector on both sides that the box would fit perfectly in the routed spot. Add electrical tape inside the box and mark polarity of the batteries.
Step 14: More Soldering
Shorten transistor's legs and solder the "base" leg of the transistor to the middle connector of the sensor. Then, solder two short wires to the RGBW LED strip's connectors of your preferred color (negative wire (-) goes to R, G, or B color).
Step 15: And More Soldering
Solder two extension wires to the positive and negative connectors of the sensor.
Then solder negative wire from the LED strip to the "emitter" on the transistor.
And then solder three positive wires together: one from the sensor, other from the LED strip and last onefrom the batteries.
Step 16: Final Soldering
Finally, solder negative wires from the sensor and from the LED strip to the "collector" on the transistor. Add electrical tape around unprotected wires.
Step 17: Preparing Led Strip for Gluing
Cut away non-sticky tape under RGB LEDs on the strip and place sensor and the batteries in place.
Step 18: Led Strip Gluing and Finishing Lighting System
Put some super glue on the previously cut spots and then glue the LEDs to the small blocks. Secure wires with hot glue. If other components doesn't hold well secure them too. Add Li-Ion 18650 protected batteries.
Step 19: Final Touches
Add the clock mechanism, tighten it, and add clock arrows. Put in one AA battery for the clock and add some more electrical tape on the sensor to prevent from accidental short circuit if you hand the clock on a metal hook or a nail.
Step 20: You Made It!
I hope this instructable / video was useful and informative.
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