Perspex Enclosure and Stencil For World Clock

7/25/2019 Perspex Enclosure and Stencil For World Clock

1/17

Word Clock

Perspex Enclosure andVinyl Stencil Construction

Notes

Doug JacksonVK1ZDJ

Marc !"11

V1#1


2/17

Licence

$e Word Clock Design% PC& layout% Manual% and 'ir()are is Copyrigt !""*% !"1"%

!"11% +y Douglas Jackson% VK1ZDJ#

$is Design% PC& layout% Manual and 'ir()are is licensed under te $,P- .pen/ard)are 0icence Non2Co((ercial3# )))#tapr#org4NC0#

Per(ission is granted 5or any+ody to6

Modi5y te docu(entation and (ake products +ased upon it% pro7ided you do not(ake (ore tan ten units in any t)el7e (ont period#

8se te products 5or any legal purpose )itout li(itation# Distri+ute un(odi5ied docu(entation% +ut you (ust include te co(plete package

as you recei7ed it#

Distri+ute only on a non2pro5it +asis% carging no (ore tan te actual cost o5 parts%asse(+ly% and sipping#

Distri+ute products you (ake to tird parties% i5 you eiter include tedocu(entation on )ic te product is +ased% or (ake it a7aila+le )itout carge5or at least tree years to anyone )o re9uests it#

Distri+ute (odi5ied docu(entation or products +ased on it% i5 you license your(odi5ications under te ./0#

Welcome

$anks 5or deciding to (ake tis great little clock pro:ect# ; a7e really en:oyed designingand de7eloping it o7er te last 5e) years#

$ere are so (any )ays to construct a )ord clock# ; a7e +roken asse(+ly do)n into7arious docu(ents < $is docu(ent details te construction o5 a 7inyl display stencil3 anda perspex enclosure#

=ou )ill 5ind tat construction o5 tis clock is 7ery si(ple and (etodical#

&e care5ul )it your (easure(ents% and sa5ety conscious )en you are using cuttingtools% and you )ill 5ind tat te co(pleted pro:ect )ill +e an a(a>ing con7ersation starter

5or years to co(e#
http://www.tapr.org/NCLhttp://www.tapr.org/NCL


3/17

Parts List

$ere are t)o 7ersions o5 te stencil and enclosure kit < a sort 5or( kit tat :ust pro7ideste cut 7inyl stencil% re9uiring you to purcase so(e Perspex seets to co(plete tepro:ect% or a 5ull kit containing all o5 te Perspex as )ell# Perspex is easily a7aila+le 5ro((any sign )riting e9uip(ent suppliers# Most suppliers )ill cut te seets to te re9uiredsi>e

$e 5irst ting you need to do is to 7eri5y tat you a7e all o5 te necessary co(ponentsre9uired to asse(+le your 5ront stencil /ere is te co(plete parts list#

Front

?""(( x ?""((Perspex seet?(( clear3

1

?""(( x ?""((7inyl stencil ;n kit3

1

Enclosure

Side Support

?(( &lack3

@"(( x !A"(( !

$op Supports

?(( &lack3

@"(( x !@B(( !

&a55les ?(( &lack3 !(( x !@B(( 1"

0ED ,rray Support

?(( Wite3

!@B(( x !@B(( 1

-ear Co7er

?(( &lack3

!A"(( x !A"(( 1

-ear Co7er Mounts

?(( +lack3

!"(( x !"(( B

'ront stencil (ountingstrips

?(( &lack3

!"(( x !@"(( !

Enclosure scre)s ?(( x 1"(( coarsesel5 tapping scre)

A

,dditionally% you )ill need so(e plastic glue )ic is co(pati+le )it your perspex seets

< talk to your perspex supplier 5or te correct glue# ; use ;PS )eld2on 1@ < Sol7entce(ent 5or acrylic 5or (y o)n pro:ects#


4/17

Stencil Construction

Start asse(+ly +y (aking our stencil# =ou )ill a7e +een pro7ided )it a pre2cut 7inylstencil# $is needs to +e attaced to a clear perspex +acking seet to pro7ide rigidity#

$e 7inyl stencil as supplied )ill +e larger tan re9uired# $is is so as to pro7ide extra(aterial 5or 7ariations in 5ace si>es# We need to cut te 7inyl stencil to te 5inal si>e o5your perspex seet% allo)ing an extra 1"(( allo)ance around te edges#

0ay te Perspex +acking on top o5 te stencil % and (ark out a cut line% ten using astraigt edge and a sarp o++y kni5e or scalpel3% cut te seet to si>e#

NOTICE

Ensure that when working with the vinyl sheet, you work inan environment that is clean an relatively ust !ree"

I! ust #articles are ca#ture $etween the vinyl an the#ers#e% $acking, raise $u$$les will a##ear that can not $eresolve, maring the a##earance o! the !ront o! the clock"

I shoul o all o! my vinyl work in the ining room, not inthe garage" &Note to sel! ' Thank (rs )ackson !or $eingaccomoating*+


5/17


6/17

$urn te Perspex o7er and using a s9uegee% or your and% gently 5latten te stencil out tore(o7e te excess )ater 4 soap (ix# 8se so(e paper to)el to clean and dry te stencil asyou expel li9uid# ,s you expel te li9uid% you )ill notice tat te stencil locks onto teacrylic seet# We )ant tis gluing action to appen# Do not ru+ te 5ront ard% as you )illda(age te sur5ace# .nce you a7e expelled all o5 te )ater4soap (ix% and tings arelooking 7ery 5lat% (ar7el at your )ork% and lea7e it to adere 5or an our or so#

Cut te 7inyl seet to te 5inal si>e on te perspex < ; lo7e te look o5 allo)ing a ? < ((clear edge to 5ra(e te +lack 7inyl# =ou (aypre5er to cut te 7inyl e7en )it te edge#

Next% looking at your stencil% you (ay 5ind tatso(e letters need to +e re(o7ed% )ile te centreo5 oter letters .% ,% -% D% etc3 need to +etrans5erred 5ro( te +acking seet to tePerspex# 8se a sarp kni5e to gently re(o7e teextra 7inyl letters% and to trans5er te centre o5 teletters to te Perspex#

;n tis poto% ; re(o7ed te air andsoapy )ater +e5ore ; 5illed te letters in< you are 7ery )elco(e to do tesesteps in te order tat you are (ostco(5orta+le# -e(e(+er < Fentle

pressure is all tat is needed to re(o7ete )ater 4 soap (ix#

;t is unlikely tat you )ill a7e any +u++les le5t% +ut i5you do% o7er te next )eek or so% any le5t o7er tiny airpockets )ill tend to (igrate a)ay +y te(sel7es#

$at co(pletes te stencil asse(+ly#

En:oy looking at it% and ten put it a)ay so(e)ere sa5e )ere it )onGt get da(aged#

No) is a great ti(e to a7e a +reakI#


7/17

Enclosure Construction

/a7ing 5inised te 5ace% )e need to continue )it te asse(+ly o5 te enclosure#

.ur enclosure is (ade 5ro( ?(( Perspex seets tat are eld togeter using a 7inyladesi7e# ,s (entioned in te parts list% you )ill need so(e plastic glue )ic isco(pati+le )it your Perspex seets < talk to your Perspex supplier 5or te correct glue# ;tis a sol7ent tat actually dissol7es te ,crylic (aterial tat te Perspex is (ade 5ro( so itensures tat te :oints are extre(ely strong#

Start +y placing te stencil ',CE D.WN onto a so5t sur5ace to protect te 7inyl 5ace# We)ill +e using te stencil as a te(plate to ensure tat )e place te +a55les in te correctpositions# =ou (ay like to use a piece o5 tracing paper to (ark out te locations o5 te)ords on te stencil% and use tat to )ork on instead#

&e5ore anyting is glued intoposition% ensure tat e7eryting 5itstogeter +y Gdry 5ittingG te piecestogeter using (asking tape as a

:ointing (aterial#

$e @"(( x !A" (( pieces arete sides% )ile te @"(( x!@B(( pieces are te tops and+otto(s

-e(e(+er tat te +a55le pieces sitagainst te +ack o5 te 5ace plate#


8/17

.nce you are appy )it te 5it o5 te pieces% re(o7e te protecti7e paper 5ro( tePerspex% and glue te outside edges o5 te enclosure togeter# Wen gluing% use a tin+ead o5 glue along te entire edge o5 te seet to +e attaced# &e care5ul at tis stage% tokeep te orientation o5 te sides and top te sa(e as during te dry 5itting# ,lso +e care5ul)it te glue to ensure tat it does not 5lo) 5ro( te tu+e o7er e7eryting% (aking a (ess#

8se adesi7e tape as a te(porary support 5or te edges o5 te enclosure )ile te gluesets#

.nce te sides are :oined togeter% it is ti(e to install te +a55les# Start +y running a stripo5 (asking tape on te inside edges o5 te enclosure to protect te stencil 5ro( excessglue# Centre te enclosure onto eiter te stencil% or te te(plate you a7e created% andstart +y (ounting a (iddle +a55le co(ponent# Wen gluing% again +e care5ul to a7oiddri++ling glue e7ery)ere# &e sure to attac te +a55le so tat it is at te +otto( o5 te

enclosure% toucing te stencil# D. N.$ F08E $/E &,''0E $. $/E S$ENC;0# Justglue te ends to te enclosure sides#

W-NIN.

Fumes given o!! $y most crylic solvents are not healthy to$reathe" Ensure that when working with the glue, ae/uateventalation is availa$le"

Please read and observe all safety warnings printed on the Acrylic

solvent. These solvents can be highly toxic and give off strong fumes.


9/17

Continue asse(+ly +y gluing te rest o5 te +lack perspex +a55les# .nce glued% old te5ra(e togeter 5or a 5e) (inutes )ile te glue sets#

Co(plete te +a55les% +y turning teenclosure o7er% and attacing so(ete(porary (asking tape to old teasse(+ly togeter )ile te glue sets

co(pletely < tis sould take a+out B ours#

En:oy a cup o5 co55eeI

,5ter te glue is dry% test te )ite perspex0ED (ounting +oard 5or a good 5it < ;t

sould 5it inside te 5ra(e% lea7ing nogaps around te edge o5 te enclosure#

.nce you are appy )it te 5it% put testencil so(e place sa5e% and li+erallyapply glue to te edges o5 te +a55les% andte sides o5 te 0ED (ounting +oard% andglue te +oard into place#

,gain < )ait a 5e) ours 5or te glue toset co(pletely#

$is largely co(pletes te asse(+ly o5 te enclosure##


10/17

.nce te glue as co(pletely set% )e need to install te 0EDs on te inside o5 te ne)lycreated ligt +ox enclosures#

$ere are t)o options at tis stage < Eiter% you can use indi7idual 0EDs and resistorsWic ; 5eel is a little ugly% +ut it )orks3% or you can use so(e o5 te Gstrip ligtsG tat area7aila+le 5ro( places like e&ay#

Strip ligts are strips o5 5lexi+leplastic PC& (aterial tat a7egroups o5 0EDs and resistors pre2installed# $ey are designed to runo5 1!V DC% and a7e an adesi7e+acking (aterial already applied#$ey can nor(ally +e cut into set o5? 0EDs% as indi7idual ligtco(ponents# $e poto on te rigtso)s a typical strip ligt#

; purcased ! x 1( Strip 0igts 5orte pro:ect#

Start +e cutting te strip ligt into te appropriate lengt sections 5or te )ords to +eillu(inated# ;n te case o5 (y strip ligts% tere is a cut line e7ery ? 0EDs% so ; used ?0EDs 5or te sort )ords% and @ 0EDs 5or te longer )ords#

.nce te indi7idual )ords a7e +een cut out5ro( te strip ligts use a s(all soldering iron totin te ends < $ey are plastic coated% +utsould solder easily#

Next% re(o7e te paper+acking% exposing te sticky

adesi7e sur5ace#


11/17

Continue +y attacing te strips to te +ack o5 eacs(all ligt ca(+er enclosure# ,lign(ent is notincredi+ly critical% +ut try to get te strip centredalong te )ord# 8se te stencil as a guide# &ecare5ul )en installing te strips to (ake sure tatte and < connections are uni5or( i#e# all up% or

all do)n3 ;t doesnGt (atter )ic con7ention youuse% :ust +e consistent#

.nce te strips a7e +een stuck do)n% use a ?(( dia(eter drill and drill a s(all ole+eside te strip ligt 5or te ca+le to +e )ired troug# &e care5ul to not drill a ole in testrip ligt (aterial#

Next% old te asse(+ly up to a ligt% and (ark teoles 5or te controller to +e (ounted < )e use aligt +eind te asse(+ly to (ake sure tat teoles you )ill +e drilling )onGt inter5ere )it any o5te strip ligts#

Next% install B sets o5 sort ex stando55s 5or tecontroller to +e (ounted on#


12/17

Continue asse(+ly +y soldering a )ire +et)een all o5 te GG connections < -e(e(+er tatte controller as a co((on +et)een all o5 te )ords#

/ere is a close up o5 te connection#

.nce all o5 te strip ligts a7e +een installed% (ount te controller% insert te ri++on and)ire eac indi7idual 0ED strip# Keep a copy o5 te )iring instructions as detailed in teasse(+ly (anual 5or te ,rduino or P;C Wordclock controller (anual to elp you get te)iring rigt# ; )rote te na(es o5 te )ords on te +ack o5 te )ite 0ED (ounting seetto elp (e#

$e 5irst )ord )ired upI ,ll o5 te )ords )ired upI


13/17

/ere is a poto o5 te 5inised )iring on te +ack o5 te clock# Note te coils at te top o5te clock < $ese are te )ires 5or te t)o spare )ords < instead o5 clipping te )ire o55% ;coiled it up 5or later#

Mount te po)er connector socket#

; drilled a ole tat )as te correct si>e5or te po)er socket A#((3 and(ounted te socket and )ired it up tote +oard#

,nd apply po)er to test all o5 te )iringis correct# , sel5 test runs at startup%testing e7ery )ord +y turning it 5or 5oral5 a second# ;5 one o5 te )ords 5ailsto ligt% ceck your )iring did you get and < te correct )ay round3

00*** -un insie an show yours#ouse*


14/17

Next% )e need to co(plete te +a55les +y adding te separators +et)een te )ords#

; canGt gi7e you an exact (easure(ent5or tese% as teir si>e depends on tespacing tat you used +et)een te

ori>ontal +a55les#

; (easured eac% and cut te(indi7idually% and ten glued te( inplace using te 7inyl adesi7e#

/ere is )at te clock looks like )it te +a55les co(pletedI

Centre te enclosure on te +ack o5 te stencil% and (ark te edges# -e(o7e teenclosure% tape te sides o5 te enclosure to protect it 5ro( te glue# ,ttac te (ountingstrips to te top and +otto( as so)n in te +elo) diagra(# $e potos on te next page)ill elp )it tis stepI


15/17

/ere is a close up o5 one o5 te stencil (ounts ready5or gluing < ; set up all 5our +e5ore ; glued te stencilin place# ; si(ply used (asking tape to old te

(ount te(porarily 5or gluing#

Ceck te 5it o5 te stencil (ountscare5ully +e5ore applying 7inyl glue#

Note tat ; a7e protected te edgeo5 te enclosure using tape to ensuretat no glue can accidentally glue testencil on < te stencil as to +e a+leto +e re(o7ed )ic is )y )e use(ounts3#

/ere is a close up o5 one te (ounts% )aiting to+e glued# Note te gap +et)een te enclosureand te stencilI

.nce you are appy% apply te glue% and lea7e it it dry 5or a 5e) ours#

.nce dry% re(o7e te enclosure% and 7eri5y tat te stencil (ounts are correctlypositionedI -e(o7e te extra tape% press te stencil +ackinto place% drill te oles 5or te (ounting scre)s#


16/17

Continue asse(+ly +y (ounting te ti(e setting +uttons on te +otto( o5 te enclosure%so tat te ti(e is a+le to +e canged#

; asse(+led te ti(e +utton +oard using a couple o5 +uttons )it long sa5ts3% (arked acon7enient place on te +otto( o5 te clock% drilling te oles 5or te +uttons to go troug#

$en ; attaced te +uttons )it a set o5 s(all spacers and scre)s#

,5ter tis is done% you need to add te ta+s to te+ack panel o5 te enclosure so tat it can +e attacedto te top and +otto( )alls# Just use a +ead o5 glueto attac te strips#

; used one long strip at te top% and a set o5 strips atte +otto(# &ecause te strips are all tat olds teclock to te )all% ; re2en5orced te strips )it so(eextra +lack perspex# .nce te +ack )as dry% ; placedit on te enclosure% drilled te (ounting oles% andscre)ed it in place#

My +ack panel as a slot cut into te top to allo) teclock to +e ung on te )all# $is poto so)s telong strip at te top o5 te +ack% and te )all(ounting slot#


17/17

Wile you are )aiting 5or te glue to dry% you need to attac so(e di55user (aterial to te+ack o5 te stencil < ; used strips o5 ligt )eigt tissue eld in place using clear tape# =ou(ay use paper% +ut ; 5elt tat te paper +locked too (uc ligt#

'inally% scre) te +ack onto te enclosure% and scre) te enclosure to te stencil% andtatGs it < Mount te clock on te )all% set te ti(e% and a7e a partyI

623 $ere < tat )as easyI

Documents

Perspex Enclosure and Stencil For World Clock