How to make your own hand powered shake led flashlight.

1. Materials:

1. 1 Plastic tube with cap, length: 4, diameter 5/8 --I use small plastic shooter tubes (aka test tubes). Available at your local Dallas BBQ or online at at places like Shot wizard.
2. 1 Priority Mail USPS cardboard box or an 8X10.5 sheet of corrugated cardboard with small corrugations
3. 1 Very strong magnet, diameter should just a bit smaller than the diameter of the small tube, length should be no more than 1/4 of your tube's length. 1/2' length works
4. 300 feet Magnet wire (more or less). Find the finest wire you can get, 32 AGW is ok, 36 even better. McMaster-Carr is a great resource at good prices for it.
5. 4 DIODE SCHOTTKY,1N5817
6. 1 0.22F or 1F super capacitor OR 1 NiMH rechargeable battery, 2.4 to 4.8 Volts,
7. 1 220K resistor (size varies according to battery)
8. 1 super bright white led such as the '''RL5-W2545''' from SuperBrightLEDs
9. 1 slide switch
10. PCB prototyping board, 2x 3/4 (20 holes lengths x 7 wide)
11. Printed Board Map (download from this page)

+

1. Acrylic + Epoxy glue
2. Clear scotch tape
3. Aluminum paper (a tinny bit)
4. Color electric tape (optional)
5. Solder (lead free best)
6. Foam (the denser the better)

+

1. Soldering iron
2. Helping hands
3. Multimeter
4. Small hand Drill (optional)
5. Holder for wire bobbins (optional)
6. Pliers
7. Wire strippers
8. Scissors

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Circuit diagram for the shakelight.

The 4 diodes are used to rectify the alternative current produced by the magnet going back and forth through the coil.

Download PDFs here:
For printing
For cutting (if laser cutter) -- optional
If you don't have access to a laser cutter to cut the printed circuit map, no problem, just cut little (x) crosses where the wholes go with a small knife, you should be able to slide your components in easily that was as well.

Step X: Making the coil

About resistance of your coil --what makes it more or less successful.

Step: Close off the tube
Place the magnet inside and attach your wires to circuit, test it

Step X: Cut and prepare your perf board

Use the printed circuit design as a reference for the size of your design. You can use a marker straight on the board and cut it using a band saw or by scoring it.

Step X: Preparation of the encasing

Print the shakelight encasing PDF and glue it to the surface of your cardboard. Use rubber cement if you want to remove the map later, to remove rubber cement pour a bit of benzine on your cardboard, it will not damage the paper. Cut where the lines are red and score where the lines are green.

If you have access to a laser cutter, print the PDF setting the red to cut, green to score, yellow to engrave and black to raster.

Download PDFs here:
For printing
For cutting (if laser cutter) -- optional
If you don't have access to a laser cutter to cut the printed circuit map, no problem, just cut little (x) crosses where the wholes go with a small knife, you should be able to slide your components in easily that was as well.

Step X: Build the circuit

Before soldering the circuit, place the map card on the solderless side of the perf board. You'll use it to help position each one of your components in its place. Simply place one piece at a time through the holes of the map and all the way through the perf board. You could always cut the paper map out after you're done making the circuit, or leave it in place.

Step X: Put the pieces together

Step Last: Close it all together

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Real shopping Online

http://www.superbrightleds.com/
'''RL5-W2545''' White LED
10 x '''RL5-W6030''' White LED
Subtotal: $ 14.20 + Shipping: $ 5.00
Grand Total: $ 19.20
http://solarbotics.com
SCC3766 - 37 x 66mm Polycrystalline Solar Cell
10 x BattR10 - 4.8V / 60mA Vertically Stacked Rechargeable Battery

http://www.jameco.com
10 x 72161 1 x 621472 40 x 177949PS 1 x 263206CB 1 x 263222CB