Tonight I made a jig for notching out the eyeballs for mounting. Just used plywood, and some salvaged aluminum angle and bar stock. Eyeball goes in, cut, cut with the hotwire foam cutter, rinse, and repeat.
Pics of the hotwire cutter after the break…
Ball sits in hole. Pretty simple.
Hotwire foam cutter. Just used some 1″x2″ pieces, spring from a lamp, and guitar wire. This still needs a battery and probably a FET with a microcontroller to moderate the current. Wire is 0.5 ohms, so putting 12V directly across it is probably not the way to go.
Spring from an old desk lamp arm + piece of coat hanger. It’s really handy to have an assortment of fasteners when you want to whip up something like this. I have a good regular stock of various sizes in #4, #6, #8, #10 machine screws + washers and nuts. Also stocking 1/4″ cap screws + hardware. Getting started on 3/8″ fasteners as I build bigger things.
The far arm is fixed. The near arm pivots to apply tension to the wire. I’m anxious to light this baby up.