Make a Fancy Blue LED Raindrop Lamp out of a 2x4 scrap, some acrylic plexiglass, and some blue LEDs.
Here is a list of the tools I used, you may be able to get away with using less:
-Bench top belt and disc sander
-Various Drill Bits
-Phillips Screwdriver Bit
Here is a list of the materials I used
-Small piece of 2x4
-2 round PCBS
-9 blue LEDs
-3 black drywall screws
Step 1: Make You Wooden Raindrop (or Teardrop) Shape
A. Cut off a piece of 2x4 and use a hole saw to cut a hole through it. I had to drill a pilot hole and cut it from both sides to get the center out. You will want to cut it to roughly the same size as your round PCBs. I got mine on eBay but you could cut you own with a hole saw.
B. Sketch out raindrop your shape around the hole and cut it with a scroll saw.
C. Finalize your shape and finish with a belt or disc sander.
D. Drill your pilot holes in the face for you to attach the acrylic later. I did this so I wouldn't crack the wood when setting the screws.
Step 2: Make Your Acrylic Plexiglass Face
A. Use your wooden shape to sketch out a shape onto you plexiglass and cut it out with the scroll saw
B. Practice cutting your countersink into plexiglass scraps. You will want the screws to sit beneath the surface.
C. Pre-drill your holes so they are exactly align with you pilot holes on your wooden shape. My drill press has a laser alignment on it so this was pretty easy for me. There are other ways to do this if you don't, such a paper template.
D. Countersink you acrylic shape.
Step 3: Attach the Plexiglass to the Wood
A. Attach the plexiglass face to the wooden raindrop with 3 screws.
B. Now finalize the plexiglass shape and finish on the belt/disc sander. I sanded the front and back to slightly diffuse the LEDs.
D. Sand a small flat spot at the bottom of your shape so it will sit nicely without rolling over.
C. Set it aside and plug your soldering iron in, it's electronics time!
Step 4: Create Your LED Insert
A. Solder your LEDs and Resistor in the shape you want to your first PCB.
B. Drill a hole for the power cord through the second PCB.
C. Pull the power cord (from the wallwart) and tie a knot in it.
D. Solder the power cord to the LED board.
E. Attached the 2 PCBs with the standoffs.
Step 5: Now Put Everything Together and TADA!!!!
A. Insert the PCB stack into the wood shapes hole.
B. Align the LEDs so they look cool.
C. Impress everyone with your fancy new light.
Step 6: Mod, Hack, and Make My Design Your Own
OF COURSE THESE TECHNIQUES WOULD APPLY TO ANY SHAPE OR COLOR OF LIGHT. YOU COULD USE RED AND WHITE LEDS AND MAKE A HEART SHAPE FOR THAT SPECIAL SOMEONE. THE POSSIBILITIES ARE ENDLESS WITH THESE THREE SIMPLE THINGS. WOOD, PLASTIC, AND LEDS.
fysfys made it!