Add three tags to the circle and then cut it out. Place a sheet of clear plastic (OHP slide or old bit of packaging) over the top of the spotlight and mark a circle (water based ink) just inside the inner wall of the lamp.
#BATMAN SIGNAL LAMP SKIN#
(remember it also sticks skin better than almost anything else, so NEVER let children do this bit of the project). Most soft plug mouldings are made out of the same plastic (PVC, vinyl or rubber) as the wires and Super Glue sticks them very well. Stick the slit edge of the rubber cover with Super Glue (Cyanoacrylate). Offer the metal case up to the rubber outer housing to see where it should go and then as you put it back on put a tiny bit of glue gun glue at the wire end of the plug and wrap the rubber cover back round the metal case. Squeeze a little hot melt glue into the metal case to pot up all the wires and provide strain relief. Slip the white plastic rectangle back into the metal case and put the metal case top back on and close the cable grips back up. Trim off any hot melt that gunges out the sides. Put some hot melt on to the soldered pin ends and quickly press home the top little hard plastic cover. Putting the plug back together is the reverse of taking it apart, except that the potting agent, is the trusty hot melt glue instead of injection moulded plastic.
When you have taken it all apart you can solder the wires that go tot the LED back on to the relevant pins, see diagram. This doesn't matter at all because you are going to be soldering new ones on anyway. It does come off quite easily, but you will quite probably break the thin wires in doing so. Inside you'll find more messy rubber, you have to pick this off. Once you have done this the top case part opens up on two little semi hinges and then can be lifted off. to separate them, you first need to unwrap the top part cable grip. What you see immediately is a metal case. It might put up a little bit of resistance because it was moulded into place, but it should come off all in one piece and relatively easily. Once you have slit it you can peel the rubber cover off the metal parts. you won't, it's all protected by a metal case. Don't worry about cutting anything inside. Using a sharp craft knife, carefully slit down one side of the plug rubber outer moulding. About 1.5 to 2 hours to spare doing this project.Black and silver paint (spray or markers).Some cardboard and or foamcore (not necessary but nice).A small piece of clear plastic sheet (OHP sheet or bit of old packaging).A cheap USB Laptop light (or the appropriate LED, wire, correct resistor and USB Plug.Some thick tin foil (take out tray, or aluminum roofing / flashing tape) although thin foil will work.A couple of old packaging bottle caps (shower bottle and single serving drinks bottle, or something similar).
#BATMAN SIGNAL LAMP PLUS#
Plus there's a little bit of fun hacking apart a Series A USB plug and using the guts! You'll need It's dead easy if you have even the most basic making skills and great to try if you've never done any electronics before. don't despair, that's plenty to work with, and if you follow this instructable you'll be casting the most wicked bat shaped shadows all over your bedroom, living room and office walls. But you don't have a gigawatt three phase power supply, all you have is a measly little 5V USB. You saw Batman Begins, you've now seen The Dark Knight, and now go on admit it, you want one of those mega spotlights with which Commissioner Gordon summons the help of the Caped Crusader.
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