Tutorial Time!!
So, while working on finishing my shins, I decided to document how I installed the lights that shine out the back. Now, this is just one way to do it, there are many other ways to light your armor. So, here we go.
First, I picked out a power source. I have a ton of these battery packs on hand. They hold two AA batteries which provide 3 volts of power (enough to light up a single LED without a resistor).
The only problem was that I needed to incorporate a switch, but didn't want the switch to be floating around or visible on the exterior of the armor. My solution was to install a switch into the battery pack itself. So, I removed the cover to see what I had to work with.
I noticed that there was a bit of room where the red wire starts (not where it exits the pack, but where it is connected to the lead). So, I cut a section of the pack off, just big enough for the switch I selected...
In order to keep the wiring as neat as possible, I decided to connect the switch directly to the lead where the red wire is connected. So, I pulled the red wire out of the pack exit point...
...and cut the wire down so that only about a quarter of an inch remained, and stripped the insulation off of that.
I connected the remainder of the red wire to one of the leads on the switch...
...and secured the switch to the pack. While securing the switch, I fed the exposed wire through the center lead of the switch and soldered it into place, ensuring there were no shorts in the circuit. Then, I re-fed the red wire back through the pack exit point...
Now that I had a battery pack with an integrated switch, I build the light box. This was done with a bit of mat board and two blue LEDs (scavenged from a strand of LED Christmas lights, a great source of cheap LEDs).
Now I mentioned that 3 volts is enough to light one LED. Having two in a series would not work, so I set them up in a parallel circuit. I soldered the LED's long leads together and their short leads together.
Then, going back to the battery pack, I soldered the red wire to the LED's long leads, and the black wire to the short leads...
And with that, I had my light circuit.
Now it was time to focus on the diffuser, which would even out the glow from the two LEDs. Adam and someone else (I can't remember who) introduced the use of the side of an old CD case as a diffuser. So, I cut out a rectangular slot about an inch long and as wide as the CD part, and using a bit more of the mat board, I installed that...
When that was installed, I secured the lighting circuit into place. In doing that, I made sure that I would have easy access to the switch when the armor was on AND that the cover of the battery pack could easily be removed in order to change batteries...
When everything was in place (and I tried on the shins to ensure that the battery pack wasn't in the way, which it wasn't) I cleaned up the area around the light on the exterior of the armor (notice that the paint does not exactly match, that's the camera picking up minor differences again, first hand it's far less noticeable)...
And it was finished...
Again, this is just one way to do this. I chose this way because of the parts I had on hand. I'm sure that there are battery packs out there with built-in switches.
The shins are ALMOST finished. I've put in some strapping. The only thing left to do is install a little padding at the base to keep them from slipping down over my boots and to keep them secure and not flopping around a lot (not that they do it now, but they do it just enough to bug me).
So, I hope you all liked this mini-tut and keep watching!