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1Case
Print the base plate, top shell, retaining clip and two light panels (left and right mirrored). Heat set the knurled inserts
- 1 1/4"-20 in the bottom of the base plate for the tripod screw
- 1 M3 in the top of the base plate for the TP4056 retaining clip
- 2 M3 in the top shell sides for the light panels
- 6 M4 in the top shell to secure the base plate
Drill two M2 holes for the PIR (countersinks are printed on the front face).
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2Light Panel Assembly
This is extremely tedious: place and solder wires between each of the 12 NeoPixel buttons in the order shown in the diagram. Repeat for the other panel. At the input side of each strip, terminate with a JST connector.
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3Main Board Assembly
Place two strips of female headers to receive the Trinket. Underneath, add a 3 pin 90 degree male header (for a jumper): one outside pin connects to the Trinket's Vbus, the other to the Trinket's Vbat. The central pin is Vled to power the NeoPixel strips. Add a 100-1000uF decoupling cap between Vled and ground. Add 5 male JST receptacles:
- 1x 2 pin for Vbat input
- 1x 2 pin for the mode push button
- 1x 3 pin for the PIR (3.3V, data, ground)
- 2x 3 pin for the NeoPixel strips (shared Vled & ground, separate data lines)
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4Base Plate Assembly
Connect (solder) the battery to the TP4056 board battery input. Connect the positive output to the sliding (DPDT) power switch. Terminate the ground from the TP4056 board (negative output) and the power switch "on" output in a 2 pin JST plug to match the input on the main board.
Solder a 2 pin JST plug & wires to the mode push button to make it pluggable into the main board. Snap fit the 6mm push button into its clip. Snap fit the LiPo battery into its clip. Fit the TP4056 board in its holder and secure with a retaining clip.
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5Final Assembly
Connect the momentary mode switch, PIR, two light panels and the power cable to the main board. Fit the wires into the housing and secure the base plate to the shell with 6x M4 screws.
Now that everything is assembled, it's time to start debugging...
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