A scrap of 1/2" plywood was cut to test the thickness inside the watch and see if it would serve as a suitable brace. The scrap held the watch faces nearly parallel. The edge of the watch was traced on the edge of the scrap plywood and cut out on a band saw. The arc of wood was reduced on a belt sander until the thickness and arc matched the space between the smart watch and the inside rim of the faux pocket watch clamshell. Two more arc pieces were made by cutting and sanding bits of the scrap plywood. The tension of the wood pieces could hold the clamshell closed not they must be tucked inside when the watch was closed.
To close the gap around the rim of the watch a metal ring was purchased as part of a clevis pin. The first attempt to cut the ring on a band saw failed due to a low tooth count blade. A curt-off wheel in an angle grinder was used to trim the ends so the ring could be bent around and make a nearly complete circle. The ends were tested so they pointed to one another. The ring however was too twisted to lie flat so it would not make a good fit to fill the gap.
4mm (0.156") diameter plastic rods were purchased from a hobby store. Solid rods, not tubes. A capped piece of 1 1/2" PVC with a hold was selected since its diameter was close to the faux pocket watches. A plastic rod was inserted into the ole for holding and a heat gu was used to bend the plastic around the PVC. The plastic rod was trimmed to keep the most uniform parts of the cycle and reheated to complete the circle. The circle was slightly larger than the faux pocket watches so it was trimmed until touching the ends created the correct diameter. The circular rod was heated uniformly and pinched shut until it cooled. The ends were trimmed until the hinge could pass between them to shut.
The plastic and wood were painted with modeling paint called "Gun Metal" which seemed to be a close match to the watch. The plastic's flexibility allowed the buttons to be pressed without appearing conspicuous.
To do:
Scrap of plywood holding the clamshell apart
Arc traced on plywood
Refining plywood arc
Only three were needed but four were made
Plywood pieces surrounding smart watch
Clamshell, smart watch, and plywood spacers
Side view showing parallel watch faces
To close the gap around the rim of the watch a metal ring was purchased as part of a clevis pin. The first attempt to cut the ring on a band saw failed due to a low tooth count blade. A curt-off wheel in an angle grinder was used to trim the ends so the ring could be bent around and make a nearly complete circle. The ends were tested so they pointed to one another. The ring however was too twisted to lie flat so it would not make a good fit to fill the gap.
Using an angle grinder to cut metal ring
Metal ring cut enough that it can form a complete circle
Bending the wire ring with a piece of steel
Twisted ring unsuitable for use in this project
4mm (0.156") diameter plastic rods were purchased from a hobby store. Solid rods, not tubes. A capped piece of 1 1/2" PVC with a hold was selected since its diameter was close to the faux pocket watches. A plastic rod was inserted into the ole for holding and a heat gu was used to bend the plastic around the PVC. The plastic rod was trimmed to keep the most uniform parts of the cycle and reheated to complete the circle. The circle was slightly larger than the faux pocket watches so it was trimmed until touching the ends created the correct diameter. The circular rod was heated uniformly and pinched shut until it cooled. The ends were trimmed until the hinge could pass between them to shut.
4mm plastic rods
1 1/2" PVC and heat gun
Heat gun used to wrap rod around PVC pipe
Plastic rod being wrapped around PVC pipe
Nearly full circle of plastic rod
Trimming plastic rod with wire cutter
Shortened plastic rod segment
Reformed plastic circle
Plastic rod around plywood pieces
The plastic and wood were painted with modeling paint called "Gun Metal" which seemed to be a close match to the watch. The plastic's flexibility allowed the buttons to be pressed without appearing conspicuous.
Painted pieces
Watch shown from side
Watch shown from top
To do:
- Find a suitable background. Gears or faux metal
- Add copper contacts on the side of the bezel
- Add lens to the back over the background
- Find a method to securely close clamshell
Journal Page 1
Journal Page 2
The rest of the posts for this project have been arranged by date.
A list showing of all the final posts of COMPLETED projects.
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