Cardboard Boba Bucket - Range Finder

We're getting very close to the end of all my old progress pictures. I did get the helmet down the other day intending to do some more painting, but gave up before I'd even started, it's just so tedious, marking out all the shapes.




Originally Posted 27-Jul-2009


Next up is the rangefinder housing. If I remember correctly this part isn't detailed in either of Antman's threads 
(which I have been following fairly closely) So I'll try to show a bit more detail.

First of all print out a set of WoF's templates from the gallery.

I'm using 1mm thick mattboard (scavenged from an old sketch book)
So I then began to mark the various places I would have to trim 1mm off of to keep the correct shape.

The dotted lines show where I'm going to angle both edges at the corner rather than just trim one of them.

Here are the pieces cut out.

I began to angle some of the pieces with a knife and sandpaper. I also drilled out the LED holes using a 5mm wood bit.

Then I just began assembling all the pieces.

I had to be careful, trying to make sure the sides were square.

One of the pieces didn't quite fit, overtrimmed, but I'll sort that out later

After letting it dry a while I decided to paper mache' the inside, to cover the small cracks and strengthen it a bit.

Then I brought out my circuit and did a test fit, bending the LEDs into roughly the correct place.

The circuit fits easily into the housing. The only problem is that it infringes on the lens' space more than I would like. 
But I can't be bothered to move all the stuff onto a smaller board.