This project is by Bob from I Like To Make Stuff. This DIY project not only allows you to create a functional piece of decor but also enhances your woodworking skills while adding a unique touch to your home.
Step 1: Gather Your Materials
To begin with, you will need a clock kit. Bob suggests sourcing one from eBay or Amazon. These kits typically include all necessary components and detailed instructions. The instructions often illustrate where to place each component, making assembly straightforward.
However, if you encounter a kit with instructions in a foreign language, don’t worry! You can rely on your basic knowledge of electronics and the visual layout of the board to guide you through the assembly process.
Step 2: Assemble the Clock Circuit
Once you have your clock kit, start by placing all the components on the board according to the layout. Bend the wires to secure the components in place and then solder each connection. The integrated circuit (IC) acts as the brain of the clock, so ensure you install it properly.
Next, find an appropriate power adapter. Bob recommends keeping a stockpile of old cell phone chargers, as they can be quite handy. In this case, he used a 5-volt charger that he had on hand. Strip the wires and connect them to the board.
Once everything is connected, plug in the adapter. The clock should power on, displaying two tiny buttons on the front for setting the time.
Step 3: Build the Clock Box
With the clock circuit complete, it’s time to create the box that will house it. Bob used scrap pine wood for this project. The specific type of wood isn’t crucial, but the size is important. Start by measuring out the dimensions needed for a cube.
Find the center point of the front piece of wood and determine where you want the display to sit. Trace around the clock board to mark where to notch out the wood. Use a Forstner bit to remove most of the material, then refine the corners with a chisel.
Step 4: Prepare for Button Installation
Before continuing, locate where the wires will feed through the back of the clock. You will need three holes: one for the power wire and two for the buttons. Cut four lengths of wire, strip the ends, and pre-solder them for easier attachment.
Solder one wire to the back of each button, as each button will require two wires. Next, drill holes in the back panel to accommodate the buttons. Measure carefully to ensure proper placement, and use a Forstner bit to thin out the material around the holes.
Step 5: Assemble the Box
With all pieces prepared, use a brad nailer to connect the parts of the box. It’s essential to ensure that the cutouts are the right depth, so the clock sits flush with the wood’s face. If the wood is slightly warped, don’t worry; it can still work out fine.
Next, you will start on the veneer. Cut oversized pieces of veneer and apply them two sides at a time. Wait for the adhesive to dry before proceeding to the other sides. Trim off the excess veneer carefully, allowing for a little overlap to sand down later.
Step 6: Final Touches on the Veneer
When applying veneer, it’s crucial to keep the edges as close as possible, especially on the front face where the clock display will be visible. Once the veneer is applied, trim any excess glue and veneer using a knife and sanding block for a flush fit.
For the front veneer, lightly trace where the clock sits so you don’t apply glue in that area. Use a spray adhesive to secure the veneer and the clock display. After it dries, trim the excess veneer and open up the holes for the buttons.
Step 7: Install the Buttons and Power Cord
After preparing the veneer, install the buttons by pushing them into their respective holes. Drill a final hole for the power cord to come through the box. Measure the center of the back panel and drill a 3/8 inch hole.
Cut the power wire in half, strip the ends, and feed the two wires from the adapter through the hole. Tie them in a knot to prevent them from pulling back out. Use wire nuts to twist the wires together securely.
Step 8: Evaluate and Improve
After completing the project, Bob reflects on the process and identifies areas for improvement. He suggests spending more time on the veneer work for a cleaner finish. Additionally, he recommends using veneer without figuring to avoid obscuring the clock numbers.
Finally, Bob mentions considering a different clock display, as the current one isn’t bright enough and operates on a 24-hour format, which may not be ideal for everyone.