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DEvan's DIY Pages PROJEKT #1: LED Marker Beacon - Page 2 - Parts List and Instructions Parts List (for each unit): (Quantity) Desription - Supplier & Item Number [Price] (1) 5mm diffused red flashing LED - AE #LED-4 [$0.45] (1) PN2222A NPN transistor - AE #PN2222A [$0.16] (1) LT4W55-2120-EA phototransistor - AE #PTR-1 [$0.65] (1) 1/4 watt 1K ohm resistor - AE #R-1K [$0.05] (1) AAA battery holder w/ leads - AE #BH-42 [$0.65] (1) plain perf board, 2 3/4" X 3/8" pc. -RS #276-1395A [$0.22] (1) 3/16" X 1 1/2" eye bolt with hex nut -AH [$0.49] (1) #10-24 hex nut with nylon insert -AH [$0.12] (2) #10 flat washer -AH [$0.04] (1) #6-32 X 1/4" bolt with hex nut -AH [$0.08] (1) disposable centrifuge tube, 50ml - CL #21-5095 [$0.72] [parts total=$3.63 ea. + 2 AAA batteries] Supplier Codes: AE= All Electronics - www.allelectronics.com RS= Radio Shack - (local) AH= Ace Hardware - (local) CL= Carolina Biological Supply - www.carolina.com Tools Needed For Assembly:
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Step-By-Step Instructions: -01- Measure and mark perfboard cut lines using ruler & sharpee -02- Cut perfboard in one of two ways: -2A- Score line with razor knife ----- Carefully break piece away while holding pliers along scored line -2B- Place perfboard in vise ----- Carefully saw pieces apart with hacksaw -03- Sand cut edges of perfboard with 100 grit sandpaper if needed -04- Mark and drill mounting hole in perfboard with 1/8" drill bit -05- Mark parts placement on top side of perfboard with sharpee -06- Solder parts onto perfboard ----- Pop switch into place and bend pins toward each other with a screwdriver tip ----- Bend leads of resistor as shown and slide in place ----- Bend top lead of resistor up across the 2 switch pins on the right ----- Solder to both pins, clip off excess ----- Bend second lead of resistor toward the center of the PN2222A ----- Bend leads on the PN2222A as shown and insert in place ----- Bend top lead of PN2222A to top of resistor (switch end), solder and clip excess ----- Bend center lead of PN2222A across the second lead of the resistor and solder ----- Bend bottom lead of PN2222A down toward LED ----- Insert LT4W55 as shown and bend top lead across the lower resistor lead (center pin on PN2222A), solder and clip excess ----- Bend leads on flashing LED as shown and insert in place ----- Solder left lead to bottom of LT4W55 and clip excess ----- Solder right lead to bottom of PN2222A and clip excess ----- Insert black lead of battery pack into hole between LT4W55 and LED and solder ----- Strip an extra 3/16" of insulation from red battery lead and insert above switch ----- Bend lead across center pins of switch and solder to both pins ----- Fold battery wires and mount perfboard to battery holder with bolt & nut -07- Shorten eye bolt ----- Place eye bolt in vise and cut about 1" off of threaded end with hacksaw ----- File cut edges if needed and check to see that nuts still fit -08- Diffuse container tip ----- Sand cone shaped tip of centrifuge tube lightly with 100 grit sandpaper (This helps diffuse the light emitted by the LED so it can be seen from all directions) -09- Assemble cap ----- Drill hole in center of cap with 1/8" drill bit ----- Spin top nut onto eye bolt as far as it will go ----- Twist cap onto eye bolt until its up against top nut ----- Spin bottom nut onto bolt and tighten pair together with pliers -10- Batteries, testing and use ----- Insert 2 AAA battteries and flip switch to "ON" position (left) ----- Carefully slide unit LED first into tube poking excess battery wires in last ----- Screw top onto unit and test - LED should flash unless its in bright light ----- Unscrew top and gently pull battery wires to slide unit out and switch back to "OFF" ----- Can be transported with batteries in place and switched on when setting up camp ----- Standard alkyline batteries will last for 7 to 10 nights of camping without replacement ----- Remove batteries for long term storage and reload with fresh when packing up gear |
Here is the printable version of the parts list and circuit design, along with complete parts layout diagrams for my markers.  Click for full size (printable) image. |
© 2005 DEvan Brown