Considering a different approcah to protruding LEDs

[PeterPan]

Update... my 20 mil thick PETG plastic arrived before the Envirotex, and I decided to give it a try first, and on this this product...



Here I was formerly just laminating my control panel labels, but getting mixed results from trapped air bubbles, etc. Since I needed to add some new  LEDs (next to each number) on this project anyway, I decided to shift gears ans start with that one. I removed the original label, punched my holes for the switches and new LEDs in a fresh label, and then did the same for a clear PETG cutout. I did NOT NOT drill holes for the new LEDs because my whole point of this post was to see if I could recess them.  (remember, that was the original post title    ). The older LEDs still protrude, but I may change that too. I applied the new label after drilling the new LED holes, covered the device with my clear PETG, and put all my switches back.

Folks, I couldn't be happier with the result! This unfortunately fuzzy closeup of one of the new LEDs doesn't do it justice (my camera is crap!)





But despite the lousy photo, I can see that this is a prefect solution. The 20 mil PETG fits perfectly in the recessed label areas with room to spare. Its giving a bright clear finish, much better than my earlier lamination attempts. And since the new LEDs are under the plastic, I now have a pedal that is a little more spill proof. I don't think I could have gotten a coating as thin as 20 mills with the Envirotex.

So there is one remaining issue. Even if I recess ALL the LEDs, Its still not totally "spill proof". Even though the label and PETG combination is recessed enough so you can't grab it with your nail, a liquid spill would still quickly work its way to the label under the plastic by capillary action.  The labels are supposed to be weather proof, but that doesn't mean I'd welcome trapped moisture. So what I'd like to do is add a very thin bead of some kind of sealer between the edge of the PETG covers and the edge of the recess. Maybe clear silicon sealer would work, if I could find it with an accurate applicator that's better than a window/tub caulking gun.  Any thoughts?

[davent]

You can get small needle tipped applicators that should work with the Envirotex...

For example



http://www.fisheriessupply.com/west-system-807-syringes

[PeterPan]

You can get small needle tipped applicators that should work with the Envirotex...

For example



http://www.fisheriessupply.com/west-system-807-syringes

Hmm!!! I actually have a couple of those syringes... even one with a nicely curved end. I guess if I used Envirotex (or just about anything) through one of those, it would be a one shot deal (toss the needle after use). I guess if I did all my prototypes at once it would be worth it.

But I wouldn't mid finding something else I could use that is a little more forgiving. If I was able to use something like silicon, at least on the off chance I decide to remove the cover to re-work something, it wouldn't be totally impossible.

[karbomusic]

You can get small needle tipped applicators that should work with the Envirotex...

There is a chance there is 5-minute clear epoxy that would set much quicker assuming it remains clear. I'd sort of hate to mix Envirotex up and wait 4 hours just for that tiny hole. Also remember any clear liquid will likely completely defeat the LED lens unless that is desired like I did in my picks way up ^there somewhere.

[Jdansti]

>Its still not totally "spill proof". Even though the label and PETG combination is recessed enough so you can't grab it with your nail, a liquid spill would still quickly work its way to the label under the plastic by capillary action.  The labels are supposed to be weather proof, but that doesn't mean I'd welcome trapped moisture. So what I'd like to do is add a very thin bead of some kind of sealer between the edge of the PETG covers and the edge of the recess. Maybe clear silicon sealer would work, if I could find it with an accurate applicator that's better than a window/tub caulking gun.  Grin Any thoughts?

If you seal the edges with silicone, you might want to avoid getting any under the plastic where it would spread unevenly and not look good. I wonder though why you'd want to make it spill proof. Normally pedals take more mechanical abuse from footwear and from being dropped. Sure you could accidentally spill your beer on them, but that usually isn't a problem. Could it be that you're trying to protect the labels from liquid more than trying to prevent moisture from entering the enclosure?

[PeterPan]

>Its still not totally "spill proof". Even though the label and PETG combination is recessed enough so you can't grab it with your nail, a liquid spill would still quickly work its way to the label under the plastic by capillary action.  The labels are supposed to be weather proof, but that doesn't mean I'd welcome trapped moisture. So what I'd like to do is add a very thin bead of some kind of sealer between the edge of the PETG covers and the edge of the recess. Maybe clear silicon sealer would work, if I could find it with an accurate applicator that's better than a window/tub caulking gun.  Grin Any thoughts?

If you seal the edges with silicone, you might want to avoid getting any under the plastic where it would spread unevenly and not look good. I wonder though why you'd want to make it spill proof. Normally pedals take more mechanical abuse from footwear and from being dropped. Sure you could accidentally spill your beer on them, but that usually isn't a problem. Could it be that you're trying to protect the labels from liquid more than trying to prevent moisture from entering the enclosure?

I sadly spill my beer on pedals a bit too often to NOT be embarrassed about it  .

But anyway, it was the recent addition of these new LEDs that prompted me to worry a little about spills getting in, and frankly I was looking for a better way to protect the labels fro footwear, as you mentioned. Recessing the LEDs under the plastic labels helps in that regard too, as its one less thing to kick or get caught on something. But unlike my previous lamination protection, I now have these edges where any liquid will stay forever, as will likely foul the label eventually. So instinct tells me to put something round the edge. I mentioned clear silicone because its so thick, it pretty much seems to just stay where you apply it, and doesn't tend to seep into thing unless you apply it with a lot of pressure. But I'm open to other possibilities.

[Jdansti]

BTW- I forgot to mention that your pedal looks great!   

[PeterPan]

BTW- I forgot to mention that your pedal looks great!   

I really appreciate that. This is part of a multi component system that has required lots of time invested in the electronics, the firmware, and the cosmetics. The firmware time invested rapidly overtook the electronic dev time, mainly because there is no end to programming improvements. So that was expected. But I dare say that time and materials spent on cosmetics and construction issues have rapidly caught surpassed coding time! Maybe I'll be successful enough rolling out this thing in 2015, to end up being able to build 100 or more. THEN I can have my holes (round and square) pre-cut, factory perfect laser engravings instead of home made labels, and a bunch of other "niceties" that don't pay when you're just making a dozen prototypes. For now, its all on ME!    Its nice to hear from outsiders when its looking good because on my own, all I ever tend to see is the shortcomings.

[trjones1]

Why file? That will only mess up the nice glossy finish of the LED. Flat top LED's already serve that purpose.

I use these along with a plastic bezel.  I like the look and the viewing angle is great.  More than you'll ever need for something that's going to be sitting on the floor.  An added bonus is that they don't burn out your eyes when you look straight at them like domed high intensity LEDs do.



Edit: I just saw the Envirotex discussion on this thread.  I've covered about a dozen pedals in Envirotex, including this one.  I always used disposable plastic cups and spoons for measuring, mixing and application.  Just cover up the pedal while it's curing.  I use a cardboard box.