Removed the inner C track on the front!

The LED ring for the new blade

I installed a cast ring in the routed track on the back side of the disc last night.  I am happy with these cast replacement rings but I am not as pleased with my routing ability.  I guess I was hoping for something that looked cut by a laser.  Only one of the preorders had requested this process so I am going to clarify what her expectations were in this area.

I will also try injecting some black adhesive from inside to conform to the edge of the plastic (which is crisp) because it looks worse when illuminated.

Routed out the back C in 13 minutes.  Finished cutting out the battery compartment in 10 minutes but it doesn't look like there will be room left to change out the A23 battery.

Inner C rings (cast on left, original on right)

 

Finished routing including the little notches

Got the replacement parts, good as new!

Everyone is sick in the family except me so up at 4:30am with my daughter... probably won't last a long time tonight.

I have spent about 20 minutes so far cutting posts and I would say I am more than half done.  The factory battery is going to take most of the remaining time.

I also spent about 25 minutes mounting the LEDS on the blade but that is done.  Now I need to do the wiring.

Cutting the tabs off the factory blade only took about 10 minutes with a box cutter.  I used thick cardboard on my work surface to protect it and it had a nice effect of giving the blade some friction so I didn't accidentally cut through the rim itself.

Casting the blade and the two C rings takes about 3.5 ounces of PET and a 15 drops of catalyst per ounce.

One of the two molds are done... waiting for more urethane to be delivered Friday so I can finish.

I started growing concerned about the kids playing with the molds and stuff so I moved everything down to the man-cave (basement) this morning.

New proof came in... gave them the go-ahead!

Another problem is the subminiature slide switch.  The one that is installed at the factory is part of a PCB and has a 3cm span from post hole to post hole but I can't find a panel-mount switch like that for sale.  So now it looks like I am going to have to put my own board on there just to install a switch at that location.  More on that after I hit up the local Radio Shack.

Inner C Ring Light Test