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Step 17: Building the Chatterbox

The Chatterbox is constructed as follows:

Step 1: Drill one end of the plastic enclosure for the pushbutton and speaker 'grill'. The holes were laid out in an AutoCAD drawing and the final design was printed onto an adhesive label at full size. The label was attached to the box and the holes were drilled using a Dremel 4000 fixed to a Dremel bench stand.

Step 2: Cut a slot a few millimetres deep and slightly wider than the ribbon cable at the top of the opposite end of the box.

Step 3: Cut the ridge under the lid to match the ribbon cable slot. This is necessary so the lid can be fully screwed into position without crushing the ribbon cable.

Step 4: Construct the 'power loom' by soldering wires to the pushbutton, PP9 battery clip and the UNO R3 power plug. The latter was taken from a 'universal' laptop power supply kit as the correctly sized plug is right angled so it fits neatly in the Chatterbox. Take care to ensure the correct polarity of the power plug.

Step 5: The speaker connections are created from Dupont wires featuring suitable sockets for attachment to the KA02 speaker pins.

Step 6: Cut a divider from white Plasticard. This is cut to fit in the box firmly and has a corner cut off to allow wires to pass through.

Step 7: Install the speaker, pushbutton, power loom and the divider as shown in the photograph. The divider is slightly bowed by the speaker - this helps to keep the speaker in position. A piece of foam rubber is pushed between the speaker and the pushbutton to stop any sideways movement.

Step 8: Check that the wires pass under the cut corner of the divider.

Step 9: Cut a second divider. This also has a cut corner for the wires, but also has cut-outs for the UNO R3 USB socket and power plug.

Step 10: Install the second divider into the case routing the wires as shown in the photograph. The separation of the two dividers is the thickness of a PP9 battery as the gap forms the battery compartment.

Step 11: Cut a piece of dense white foam rubber to form the base of the battery compartment. A cut-out will also have to be made to accommodate the UNO R3 USB socket. Install the foam rubber between the dividers.

Step 12: Cut another piece of dense white foam rubber to fill the end section of the battery compartment. This will need a cut-out to accommodate the UNO R3 power plug. Install the foam rubber between the dividers.

Step 13: Temporarily attach the clip to the PP9 battery and install it in the battery compartment to ensure it is held firmly. The battery wires pass neatly under the battery. Adjust the foam rubber as necessary.

Step 14: The Velleman KA02 Audio Shield should be fitted to the Uno R3 as shown in the photograph.

Step 15: Temporarily install the UNO R3 / KA02 in the enclosure. The power plug should fit so that the UNO is held loosely in position. The speaker leads should be connected the to pins on the KA02. If all is well, disconnect the boards from the plug and leads and remove them from the enclosure.

Step 16: Using the Dupont wires from the Elegoo kit, fashion a 17 way interconnection loom.

Step 17: Connect the loom to the interface board as shown in the photograph.

Step 18: Connect the loom to one side of the KA02 / UNO R3 as shown. Take care that the connections are made to the correct pins.

Step 19: Connect the remaining connections of the loom to the other side of the KA02 / UNO R3 as shown. Take care that the connections are made to the correct pins. See the diagram for the interconnection details.

Step 20: Carefully fold the interconnection loom so that it fits neatly in the enclosure.

Step 21: Fit the whole assembly into the box.

Step 22: Connect the ribbon cable to the interface board, guiding the cable over the top of the board and into the slot cut in the top of the case. Some excess cable should be left in the gap between the interface board and the end of the box, forming a downward bend.

Step 23: Insert a piece of white foam rubber to hold the UNO R3 firmly against the side of the case. Insert another piece of foam rubber between the interface board and the end of the case to fix the ribbon cable in place. In this photograph the foam rubber between the speaker and the pushbutton can also be seen.

Step 24: Screw the lid into place, being careful not to crush the ribbon cable.

The Chatterbox is complete!