The New Hope Obi Wan Kenobi Weathered Lightsaber
Now you see why I have this round PCB from radio shack. After buzzing out only the threads from this end of the grenade on the lathe, this PCB fits right into the recess.
All said and done, it will be a (hopefully) foolproof design, clean and simple, and easy to get apart and back together for any maintenance.
Apparently this works just fine!
Here's a minor update, maybe not so minor. I got one of my transistors installed tonight...
"But wait, sloth, isn't that kind of boring? Don't you have something else to show for yourself?"
That's right, it hides the recharge port. I found a vintage transistor, hollowed it out, shortened it, made a non conductive plug out of delrin, and glued it on the inside of the transistor cap.
Internal wiring update!
There is just enough slack in the wiring to allow the wide plug to come out enough to be able to get hold of for plugging into the grenade section, but not so much wire that it binds up on anything once it's plugged in and set back into the clamp.
Today, I got my batteries in the mail and quickly soldered them together to test to see if all the rest of my electro-fu was good to go. Turns out at this point, so far, it was!
Here is the result of tonight's work. heatshrunk and insulated the batteries, hollowed out the battery compartment a few thousandths of an inch to compensate for insulation thickness, ran a new plug between battery pack and control box, made that plug out of several others ( I wanted the colors to match, so I interchanges the crimped connections inside the plug till I got what I was looking for) I also used the stock MR speaker grille, cut it to fit the inside (so the charge port doesn't touch) and made sure all that was nice and snug.
And the CHARGING CIRCUIT HASN'T CAUGHT FIRE YET! I think I am home free, folks. We're doing a smoke test (ha) right now, but it's not hot, smoking, smelly, etc.
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