Step 1 - the cap
Firstly, the aerosol cap needs to be hollowed out to accept the LED. We used a pocket knife to enlargen the hole where the paint would have come out, until the LED fit snugly inside.
Next, we had to carve out some of the internal pieces of plastic, to allow the LED to sit inside the cap. This was fiddly and we broke one cap before getting the second one right. We used a pocket knife and long nose pliers here. Bending the legs of the LED at right angles, you can convince it into place. The fit should be as snug as possible, but don’t worry if there’s a bit of movement as the assembly will be glued together later on.
Next, we need to put a base onto the cap. After a quick look round the workshop for a piece of plastic we found that the lid of a 35mm film cannister can be modified to fit as per the pictures in the gallery above. Once modified to fit inside the aerosol cap, a hole needs to be cut (roughly 7mm diameter) to allow wires to pass through the base.
On to the push-to-make switch…
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