It's been quiet for a while. Hope y'all have started the new year on a good note.
I finally managed to find some time to solder the electronics together.
After going back and forth on what type of LEd to use for the small red one in the center of the popup arm, I decided to go for screen accuracy and use a 2mm surface-mount:
They are rather small, but after looking at a tutorial on youtube where they used double-sided tape to hold it in place while soldering, it turned out to be a lot easier that I first thought it would be.
Closeup of the main RGB LED. I sanded down the capsule. The screen used prop seems to use some kind of surface-mounted LED, but I've checked hundreds of available components and can't find anything close enough. (My guess is they used a special-made LED from some piece of scrapped Sony equipment. )
I added a couple of small 'guide wings' to the LED bezel to hold it in place. They're not screen accurate, but they won't really be noticeable once it's all put together, and precision is important in positioning the LED.
(Note: the parts in this assembly are not polished... they're to test functionality only. Once I get the final laser-cut alum parts, I'll make 'em look nice!)
Testing the little activator switch.
Video of the final electronics:
Everything works and it's under battery power. I used a piece of perforated brass as a ground plate (the mass of black wires) but in hindsight, maybe that was overkill. Next steps are gluing down all the cables where they are soldered to prevent them from snapping off when I squeeze them all into the chassis. (Repeated handling of thin wires runs the risk of them breaking at the soldering point. Some epoxy around the joint will hold them pl place so that only the insulated parts move around. It also protects against accidental shorts if a stray strand of wire should come loose!)
I was careful to measure out lengths of wires, so that the insides wouldn't have longer wiring than is needed. (Even thin wires take up a LOT of space.)
After this, I managed to cram everything into the case... video of that coming SOON. But I've decided to make the unit a little thicker, maybe 1mm or so, to give the internals some more breathing room. It's just a necessary reality of using a real working screen and circuit boards instead of a piece of plexiglass with green tape! It's not going to really matter once it's all put together though.