2019-04-14 (Su) Electronic Wind Chimes EWC

Building a proper enclosure for a piece of plastic this size would be possible and even inexpensive, but getting something made quickly is more important than making something that looks nice. LEGO was chosen since it will be possible to build something that will be possible to remove in case a more permenant case was desired and because playing with LEGO blocks was fun.

A plastic sheet from stock was selected to be cut down and serve as the base rather than making the entire enclosure from LEGO blocks. Using a rigid sheet would provide stability and wind up thinner than a whole LEGO enclosure. A mock base was built to simulate the exact size necessary. The plastic was cut on a table saw then the edges were deburred and sanded.
Plastic sheet cut and sanded for base

It took longer than expected to build a base, even though no consideration was given to color symmetry. There were supports above and below the plastic sheet to keep it in place and it worked well.
Square frame

The four corner pieces had to be secured to the board, which meant the pieces would be damaged by inserting a screw from the bottom. Accurate hole location was marked by building a jig that attached from the top and made a stack going down. LEGO Technic has a piece with holes so a marker could reach through and mark right on the plastic. One hole was made at a time and secured to ensure that each time a hole was marked, it would align with the rest of the permenantly mounted pieces.
Marking hole locations

#10 wood screws fit nicely into the center tube of a LEGO block. Countersunk screws and holes in the plastic produced flush screw heads and firmly attached pieces. 3/4" (19mm) was longer than necessary and the tip broked through the top. 5/8" (16mm) long screws would have been better.
#10 wood screws

A gateway LEGO piece kept access to the USB port on the Arduino without breaking from the LEGO theme.
Arduino's programming port

The rest of the posts for this project have been arranged by date.

First time here?

Completed projects from year 1
Completed projects from year 2
Completed projects from year 3
Completed projects from year 4
Completed projects from year 5
Completed projects from year 6

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