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Halo Sword – External Power

• • • • • • • Solder Assembly Instructions • • • • • • •

Blade Assembly

1. Lay out the parts to get an idea of how they go together. This will keep you from accidentally putting it together wrong. I recommend using a good super glue or epoxy for the plastic parts and hot glue for the wires.
2. Build the blades first. Starting with the pieces shown glue the connecting surfaces and apply a liberal amount of glue in the peg holes. There is a channel that runs the length of the blade where the LEDs will go, try to avoid filling that hole with glue.
3. Insert the pegs and screw together with 2 of the longer 1″ screws.
4. Glue connecting surfaces on the 2 parts shown with a liberal amount of glue.
5. Insert the peg and screw together with 2 of the longer 1″ screws.
6. Glue connecting surfaces on the 2 parts shown with a liberal amount of glue.
7. Insert the peg and screw together with 2 of the shorter 1/2″ screws.
8. Repeat steps 2-8 on the other half.

LEDs and Handle

This sword is powered by an external battery pack that you can put in your pocket and plug into the sword. Here are the items you will need:

1. You should have these parts, or something similar.
2. Push a strip of LEDs all the way in one a blade channel and mark the location shown above. Or measure out 31″.
3. Trim at the mark.
4. Measure the same length on the USB side of the cable. You must measure from the USB end out then trim off the excess. Look at the next picture for reference. One side should have a cut LED strip the other should have the USB end.
5. Carefully trim off the white heat shrink where the wire meets up with the LED strip.
6. You will need an 8″ 2 pair wire. Carefully strip both ends and tin them.
7. Solder the wires onto the strips as shown. Make sure positive goes to positive. Also, make sure the orientation of both strips is the same way so the strip text is right-side up.
8. Test your solder job and make sure it works.
9. Heatshrink or electrical tape the ends.
10. Put the LEDs in the blades as shown.
11. Hot glue the LEDs in place so they don’t slide out.
12. Put blades together as shown.
13. Pop in the clear inserts round side first with your fingers or tap them with a screwdriver or hammer.
14. Glue the connecting surfaces (tops and sides) of the blade and slide them into the handle as shown. Line up the holes in the blade with the holes in the handle. Once they are lined up screw in 2 1″ screws, then flip it and screw in the other 2.
15. Glue the USB from the LED onto the base plate, plug in the extension cable on the other side to make sure it’s in the right position, and let it dry in that position. Once it dries you might want to reinforce it with more hot glue.
16. Tuck in the wires then secure the bottom plate with 4 1/2″ screws. You can also apply glue to the base plate if you don’t anticipate opening it back up but I would recommend testing it before sealing the base plate with glue.
All done!!!!