mooshwerks

My rechargeable bike light (Planet Bike Roho 100) no longer takes a charge. I cracked it open and discovered the Li-ion battery is dead. Fortunately I have another battery (from an old digital camera) approximately the same size, just a little thicker. Let’s see if it all can be made whole again.

To accommodate the larger battery I printed standoff extenders (green, in image below). The original screws aren’t long enough to go through the circuit board and extenders into the original standoffs so I glued wires in place instead.

The circuit board now hovers over the larger battery, and the bent wires keep it snug.

Now , when the original parts are dry fit, a gap forms around the unit. What’s need is a collar of some sort to fill the gap. It took several attempts to get it right.

The last thing is to replace the rubber caps over the switch and USB port then glue it together!

Lastly, it’s time to charge the new battery!

My friend Phil has a vintage pair of Avalon Acoustics speakers that survived a house fire, taking some damage along the way.

The worst of it one of the speakers has a tweeter missing it’s backing magnet. I wonder if replacements exist?

This year’s card was more difficult to produce than most. To make sure it could be folded properly we created and used an automated creasing tool. Check it out:

Here’s the tool in action on a real card:

Once it proved itself, it was time to really open the faucet and go into production mode:

I drew each panel about 2x the final size. This makes it much easier to add details and watercolor. The original card design was hand built and folded on a thinner piece of paper. You can see the folding pattern highlighted in sharpie marker. Dotted lines are “valley” folds, solid lines “mountain” folds. The image on the computer screen is the CNC “tool path”, aligned with the printed card. The crease tool follows that tool path to create a precise folding pattern. Once off the machine, there is still plenty of manual creasing and folding necessary.