Amazing Casting Products: #Cre8time Makes for Extreme #GEEK (dom)... Flux Capacitor LED Night Light by Lonnie Sexton

Friday, March 13

#Cre8time Makes for Extreme #GEEK (dom)... Flux Capacitor LED Night Light by Lonnie Sexton

Today I'm sharing how to create a customized LED Night Light.

Parts/Tools:

Amazing Mold Rubber
Amazing Clear Cast Resin
Alumilite Black Dye
Mixing Cup
Mixing Stick
Mold Release
Poster Board
Hot Glue Gun
Quick Set Putty
Box Knife (razor for cutting poster board)
Xacto Knife
Sanding Block
Saw
Ruler
Sharpie
1/2" Wood Dowel
1/4" Plastic Dowel
1/8" Plastic Dowel
5/16" x 1/8" Plastic Bar
Yellow Wire
Wood Glue
CA Glue
1/4"x3" Basswood Plank
1 - GE LED Night Light - PN-
6" in. 14 awg Yellow Insulation Wire.
3 - #8 Ring Terminals

Steps:

Create Primary Object – Flux Cap
Prepare the Primary for molding
Mold the Primary
De-mold
Casting Clear Cast
Prep
Casting Cover layer
Final Assembly

PRIMARY

Cut a piece of the wood plank 2.3" x 2.7". Sand the edges and surface.

Cut 3 pieces of .500" (1/2") dowel .300" (5/16") long.

Glue the dowels to the plank shown below.

Cut 3 pieces of 5/16" x 1/8" Plastic Bar .75" (3/4") long,

and cut the corner edges off one side.

Glue the pieces with the cut edges inward.

Cut 3 pieces of 1/4" Plastic Dowel .250" (1/4") long. Drill 1/8" holes in 1 side.

Cut 3 pieces of 1/8" plastic dowel .500" (1/2") long.

Glue the 1/8" dowel inside the 1/8" hole that was drilled

in the 1/4 tube. Glue to the center of the 1/2 dowels.

Fill the tube with quick set putty.

Clear Coat. Let dry 24 hours.

PREPARE THE PRIMARY

Using double sided tape, attach the primary to the LED Night light.

Make a mold box to hold the primary out of poster board.

MOLD THE PRIMARY

Apply mold release to the primary in prepped in the mold box. Mix Amazing Mold Rubber per instructions and cover the part completely {CLICK HERE to view mixing/preparation}. Let cure.

DE-MOLD THE PRIMARY

Remove the primary part from the mold. Cut off any run off rubber.

Detach the primary from the LED Light.

Clean the clay residue from the light.

CLEAR CASTING

Place the light inside the mold. Mix Amazing Clear Cast Resin per instructions and fill the mold to the lip of the light {CLICK HERE to view mixing/preparation}. Let cure 24 hours.

Remove the casting from the mold.

CASTING COVER

Place the mold box wall or wide tape around the clear cast. Mix another batch of Amazing Clear Cast Resin per instructions. Add Alumilite Black Dye. Pour a thin layer to cover the backing. Careful not to get any on the protruding clear cast. Let Cure.

FINAL ASSEMBLY

Drill three 1/8" holes next to the posts as shown in the picture.

Cut three pieces of 1.5" 14 awg yellow wire.

Cut the Rings of the terminal crimp ends.

Strip 1/4" of the insulation off and attach the red terminal crimp to the end of the yellow wire. Glue to the top of the flux conductor.... I mean, up right clear cast post.