TK 10116's Hovi Tip speaker and amplifier

THIS POST IS STILL IN PROGRESS. CHECK BACK FOR UPDATES

7-13-15 Received the kit.

Going to mod these a bit so the fans stay mounted the way they are.

The mounting bolts are 1/4" thread. I was using 6-32 thread on the old tips.

My original setup:

I will need to up-size everything I used: flat washers, 'spiked' washers, thumb nuts, and make the fan/bucket holes bigger.

I'm debating on using rivet nuts, but the mounting area is so thin, I'm worried they may cause a crack. Also, I'm considering "beefing up" that area with nail acrylic, like I used on the legs.

I'm also going to make the battery box below,hot-swappable with these:

7-14-15 Update: 

Cut and added plugs/jacks. 

Also, I cut threads into the red connector so it would go through the nuts.

I dug through my toolbox and found these threaded inserts on a couple of furniture feet. Some 1/4 inch lock washers. (I ended up not using the lock washers).

I expanded the holes in the bucket to 1/4" and they split like I thought they would. The plastic is too thin, so I broke out the nail kit and added some for reinforcement. I also coated the outside with uv curing clear.

I also coated the tiny wires with the uv curing clear, so they would stay twisted. (they kept untwisting).

The insert was too long so I cut it.

Now I have threads to mount the switch/fan mount plate.

I used the part I cut as a finishing nut. The wire is secure under the fan/switch plate.

I believe this is the final setup.

I have two switches. One on the battery (located on the back of the bucket), and one in front if my chin. I use the chin switch to turn the setup on and off without removing the bucket.

I have both the fans and the amp/mic powered off the same battery. I will test the length of use after I mount the amp.

I removed this from the headset. It kept getting caught in my Medusa hair. I got mad at it.

First fit try. Velcro holding well.

I will test the battery duration and  performance if this current setup after dinner and pet duties...after work tomorrow.

TK 61262 July 3, 2015

Approved!

After the pics, I had to change the size of my buttons to 7/16.

Lucky for me, I still had some that size in my toolbox I used for TK4X4's door mouldings.

Member Approved!

I have graduated.

I am now TK 61262!!

Thank you all for your help in this endeavor!!

Update on application:

Got email from GML all good except buttons too big. 

I never rechecked the validity of the ab plate, aside from cutting the cod and repainting the buttons it came with, I left it as is.

Got 7/16" buttons tonight. Waiting on paint to dry.

I have to take action pics and retake just the front pics according to GML.

Tick tock ....

Hopeful Final

Well I dressed myself again.

After some teeth pulling and a Jewish Mom guilt trip on a human in the home, I got the pics taken.

He was angry teen all the way but he took decent pics and adjusted armor at my request.

Testy Test

I dressed myself!!
A bit difficult on the legs but I did get to sit down in this thing so I could reach.
I didn't put on the neck seal or the TD and the sniper plate is drying (I had to paint it).
This was a test run on fit and mobility with a bonus round of putting it on alone.

Bathroom selfie:

I used my security camera.

LoL

It's so shiny.

Currently I'm making all the pieces shiny.
One bicep I sanded and currently repainting.
Other than that, everything is done.

My poor dining room. :(

My goal is to take pics and send them in before I leave Wednesday for SWW. 

Silence of the Calves

I believe after these things testing me, I will have liver with some fava beans and a nice chianti.

The calves were about to go in the hole and get the hose again.

So I cut them.

And realized

THEY
WERE
INCORRECTLY
ASSEMBLED

All the pain and agony I went through was because of this!!!!!!

[url]https://youtu.be/wNFMPhKIZXg[/url]

I couldn't shim the back because they were too curvy and too wide for a strip.

Now I can resculpt the front and put a strip on the back and they will be fine.

In theory. I should say.

So far so good:
Stage 1:

I glued the strips to one side of each set. Magnets and clamps holding together.

when I get home I'll gluing the other sides and transferring clamps and magnets.

tomorrow morning I'm going to form the cover panels to resculpt the gap. 

I may do hook closures on the back but for now I'm using a cover strip with velcro.

Trimmed. Removing the super glue from both outside halves where the sniper plate was glued. 

Strips of sign inserted and white hot glue applied to fill gaps.

Next will be the finishing cover and crack filling.

I have a level playing field now:

Beginning acrylic sculpting:

More sculpting. 

Side note: acrylic liquid attracts flying insects. 

I have one more side to fill before sanding and shaping.

Every time I go to the door, I hear thunder, so I stopped.

I got my old Sony Smartwatch v.1 to work on my S5 so I can take my own remote pics!!

I walked around the house and up the stairs. I put on the thighs also--no pics: NSFW

(notsafeforworld, shorts had to come off LOL).

The calves fit. The velcro from past attempts, still on the back, will be removed later (before I paint). The part unseen will remain, it is the closure. I decided to not do hook elastic closures.

The fronts are formed and resculpted. I used clear acrylic to fill gaps and smooth the old raised center. I used white acrylic to reshape the top detail. 

Sally Beauty has a B2G1 sale on Beauty Secrets brand powder and liquid. 

Sanding, prepping, painting pics coming. Sniper plate mounting to follow.

Sanded more. Touched up (just like when you sand Bondo, you find dips and have to fill in.

Heated the sniper plate to resize, then gluing. Now I'm waiting on glue to dry, and acrylic to dry.

I have cover strips waiting in the wings.

Sanded, and as far as I can see...no craters. I'm going to primer them and see if I'm correct.

Currently, they are hanging to dry. I washed them after sanding.

Where is the sniper plate, you ask?

Why are there holes in one leg??

Shhhh. In time you will be told.

NO, rivets are NOT the answer.

Primer applied, now I see where I need to sand or fill.

Back to sanding once dry.

Primer has been sanded, only a few spots need fill. Will use a wire brush to remove primer from 'craters' then fill again, sand, primer...rinse repeat.

Wet primer...when this dries one more pass with 120 and 240, then primer again.

My back has thrown in the towel.

I can no longer grip my hands, stand, sit, or raise my arms to sand one more time without going into some twiching siezure.

These are the legs I'm going to paint. 

I'm sick of the sight of white.

Gloss white, 3rd light coat. Letting it set for a few days. Clear coat next.

For some reason, the ipad pictures disappear when I edit with the android.

here is the final paint and shine of the left leg.

After I returned from SWW, I tried to wear everything but I had a bit of a problem with the left leg sniper plate pinching my knee and going behind the thigh. I tried foam in the thigh and got no fix. Actually, I got a few blood blisters from the pinch.

I heated the plate while in place on the leg. It moved out far enough and I added some foam for my whacked kneecap.

No pinch...No stink...No sweat.