Step 2 - the switch
Taking the push-to-make switch, it is possible to pull off the red ‘cap’ with a little convincing, along with an internal piece of white plastic. Conveniently, there are two small holes in the switch assembly for our single - core project wire to pass through. It seems that this switch is designed to accomodate a smaller LED.
Once you have removed the cap, it is necessary to enlargen the holes to allow the wire to pass through the assembly smoothly and without friction. This is essential, otherwise the switch won’t spring back up once depressed. We used a small screwdriver for this, although a small drill bit would probably be more suitable.
We opened up the switch by carefully prising open the base of the switch to let us modify the holes more easily. Be careful not to lose the small spring inside the assembly - you will need to put it all back together again soon! Don’t worry if you snap the retaining tabs from the outer edge of the switch - you can glue the assembly back together.
Cut two lengths of project wire [around 10cm] and try to keep them as straight as possible to ensure smooth running through the assembly. Experiment with enlarging the holes until the wire passes through easily.
Next, we need to cut some holes in the spacers - the red switch cap, the white internal cap and the 35mm lid. Our holes are fairly rough, using a drill would give much tidier results. Now, put the red cap back onto the switch, without the internal white plastic part - It should click into place fairly obviously.
Now, thread the remaining spacers onto the wires, cut the LED legs so that they will fit inside the aerosol cap, and solder the wires to the LED. It may be necessary to bend the wire afterwards to get a decent fit. Put some insulating tape around one of the LED legs to stop them touching each other and short circuiting.
The next part is quite fiddly - be careful not to get any glue onto the wires, or the switch will not work! Convince the LED into the aerosol cap, then glue the 35mm lid onto the cap, that onto the white spacer, and that onto the red switch cap. Use a little more glue around the IR LED on the outside of the aerosol cap to make sure it won’t slip into the cap with use.
Leave the cap assembly to dry, and we’re ready to move onto the aerosol can…
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