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Step 19: PLACING THE PUSH BUTTON EXTENDER AND BONDING THE CASE

USING AN LED TO EXTEND THE PUSH BUTTON SHAFT

The shaft of the push button on the charging module is too short to come out through the opening on the casing. So a 3mm LED head is used as an extender.

1. The legs of the LEDs are cut off using a wire cutter.

2. The flat side of the LED is made smooth and level using sandpaper. If the LED is too small to handle by hand, use tweezers.

3. Place the LED head in the hole provided for it on the case lid as shown in the picture. Make sure the led is not tight as it is supposed to slide in and out when the pushbutton is pressed

BONDING THE CASE

1. Apply any rubber based adhesives (I used Fevi Bond) carefully along the rim on both the body and the cap.

2. Wait for 5 to 10 minutes for the glue to dry slightly and then press both the halves together. Make sure the free end of the steel axle of the encoder wheel goes into the hole provided for it on the cap.

3. Use a heavy load (I used a UPS battery) to keep both the pieces pressed while the glue dries.

A Rubber based adhesive was recommended here because in case the casing has to be opened in the future for battery replacement or reprogramming, It can be easily done by running a sharp blade or knife along the joint.