Click on the image to view

I built Elliot a switch toy about 4-5 months ago and am just now getting around to posting pics. He was (not so much anymore) obsessed with switches, buttons, and lights and there wasn't much out there to buy. I was inspired by this latch toy by Melissa and Doug. 

Step #1 - Template Creation

My first step was to create a template to work from. I'm a hack with photoshop but was able to come up with something to use as a guide when drilling the holes to accept LEDs.

Step #2 - Drilling Pattern

Next, using my drill press w/ the paper template taped onto the wood, I started drilling. I wish I would have put some more separation between letters. Not a huge screw-up though as each letter has a different color so that contrast helps.

Step #3 - Solder the LEDs and Switches

Next, I soldered the LEDs together. As different color LEDs have different voltage requirements, I broke some letters into separate circuits. I later found out that at a minimum, each circuit must have one resistor. Unfortunately, I learned this the hard way after burning out some LEDs. Wouldn't have been a big deal if I hadn't poured 4 sticks with of hot glue inside to hold all the LEDs. Wow, that stuff is hard to remove. I've also learned the importance of building the circuits before installing them. In an effort to save LEDs and given the fact I didn't have a test board, I just "winged" it this first time around. I have since purchased a test breadboard, leads, etc. All I need now is a variable bench power supply!

Step #4 - Wire Up Circuits

I know, this is a REAL mess. Some time, I'm going to re-wire. Radio Shack was also out of red wire so everything is black. Yes, it is very confusing! I shouldn't even post this picture until I get it all re-wired. Oh well!

Step #5 - Bottom Cover

I picked up a set of forester drill bits so I could counter-sink the screws on the back panel. It looks really nice. Notice how I spent time and energy making the exterior look good? :-) I've since stuck some rubber pads on the bottom.

Step #6 - Finished!

I need to get some pictures of Elliot playing with the toy. He didn't like it at first as some of the switches were difficult to press/flip. He is now old enough (almost 2) where he can manipulate each switch without getting frustrated. I'm happy to report he knows all the letters in his name now!