Led Earring

Do you like nightlife? This instructable tells you all you need to assemble LED earrings, including the instructions to make a transparent battery holder. The battery holder has an ON/OFF switch so you can turn the earring off to save on battery life.
This instructable requires medium capacity skills. Soldering is not needed.  Battery life :  approximately 20 hours

  1   Battery, non rechargeable, 3 volt,   lithium CR 2032                   

  1   Neodymium raw magnet,  diameter 6 mm, height 2 mm NdFeB, N45
        you can find it here www.supermagnete.it/eng/
 
  2   Neodymium raw magnet,  diameter 3 mm, height 3 mm NdFeB, N45 
        you can find it here www.supermagnete.it/eng/
 
  1   Screw M2x6 , inox    
        you can find it here www.ebay.com
 
  1   French Ear wire
        you can find it here www.ebay.com
 
  1   Jump ring light diameter 5mm  
        you can find it here www.ebay.com
 
  1   Small piece of plexiglas sheet , thickness 5 mm

10   cm of coloured ribbon like shoe lace
 
  1   small piece of Aluminum bar 30 x 30 mm  
        you can find it here www.item24.com/
 
  1   High Bright LED 3mm    7150 mcd   3.2V    20mA typ.   item# 751-1502-ND  
        you can find it here /www.digikey.com/


or you can buy all components in a kit here http://www.plugandwear.com/default.asp?mod=product&cat_id=96&product_id=253

or you can buy the earrings ready to wear here  http://www.blomming.com/mm/aisidream/items/led-earring

- print the drawing of the battery holder with a 1:1 ratio

- attach the drawing to the plexiglas sheet using a small piece of double sided adhesive tape

- mark the plexiglas sheet  in correspondence of  the five X  using a pin and a hammer

- drill the holes of diameter 1.2 , 3 and 5.7 mm as described in the drawing

- make a countersink of diameter 18 mm depth 4mm inserting the pilot in the center hole

- make a countersink of diameter 20 mm depth 2mm inserting the pilot in the center hole

- cut  the battery holder using a  29mm hole saw inserting the bit in the center hole. IMPORTANT: be sure that the internal diameter of the hole saw is at least 25mm

- remove the burrs of plexiglas using a diamond wheel or a small file

- drill the through hole of  diameter 1,6 mm

- thread it with the M2 threader

- drill a hole of diameter 1 mm perpendicular to the threaded M2 hole as shown in the last two pictures

- make sure that this last hole remains at the bottom of the 18 mm countersink plane

- saw a 2.5 - 3 mm thick piece of 30x30 mm aluminum bar with a central hole

- make a 10.5 mm diameter countersink,  depth 2 mm

- remove the burrs of aluminum using a small file

- insert the battery in the battery holder

- insert the 3mm diameter magnets from the rear of the battery holder until the touch the battery

- slightly lift the battery and the magnets 

- drip one drop of cyanoacrylate glue in each magnet hole, then press the battery back in its place

- assembly the M2 screw

- make a hole of  1mm diameter near the main hole  See the picture

- Bend the led terminals as shown in the picture

- Insert the led in the main hole putting the + led terminal (99% of the times it is the longer terminal) throught the 1mm hole and then insert the - terminal in the central hole

- Insert the - led terminal in the 1mm diameter hole using small pliers.  Be careful as the led terminals break easily

- fasten the screw

- The - led terminal must be totally straight or it will cause a short circuit with the positive pole of the battery
  The + led terminal should be slightly bend in order to touch the + pole of the battery

- Put the 6mm diameter magnet over the battery and move it to touch the head of the screw.  The led will light up!! 

- apply some epoxy resin on the aluminum support near the countersink and between the led and battery holder to glue all these parts together

- assembly a ribbon sorrounding the battery holder in one hole of the aluminum support, using epoxy resin to fix it

- remove the extra remains of epoxy resin using a diamond wheel or a small file

- fasten the jump ring and the French Ear wire to the aluminum support using the small pliers