Template Light Evaluation 3.2

I have just completed my prototype solar light. It is working as it should. The process of this prototype solar light began On Tuesday May the 13th.

We had a brief given to us by a man named Terry Hawkins
The brief was to modify the circuit and make an aluminium box that would fit the circuit.

We were given working solar panel lights which were purchased from the warehouse for a cheap amount of money. We disassembled the solar panel light as it was in a cheap plastic container. We then removed the circuit and all components from the cheap plastic container. We did this so we could modify the circuit and add two LED’s.

After we disassembled the circuit we put all the pieces into a bag. We then began to make the aluminium box. Terry had all the templates of the box already cut to save time. The aluminium template was cut in the cam machine because it is a lot faster than manually cutting it.

Aluminium Box

We first marked lines on the aluminium template that showed were the folding points were. We then folded the aluminium template into a box shape. Each bend was made with a 90 degree angle. Then after the box was folded we made brackets for it.

The brackets were made by cutting out bits out of scrap aluminium with the guillotine. We marked the bending points in each bit of scrap aluminium then bent them into shape at a 90 degree angle.
We then marked out the points were the rivets could go through we drilled them out using a 2.5 drill bit. We had to drill the holes in specific places to prevent the rivets hitting each other in the box. Then we attached the brackets onto the box with aluminium rivets. The bottom of the box was now completed.

Then we made the top plate of the box this again was cut out with the cam machine to save time. We marked out the folding points then bent the edges at a 90 degree angle. This was followed by drilling holes and attaching the top plate to the bottom of the box. Then I screwed it on the box. The box was now completed.

Modifying The Circuit

The circuit had to be modified. We modified it by Adding two stronger and brighter LED’s (there used to be one weak LED before undergoing modification) we also changed the circuit from series to parallel. I had a bit of trouble with changing the circuit from series to parallel. I completed a full analysis of my circuit and to my dismay there was a dry joint so I fixed this problem.

We also added a new battery connector. Once my circuit was working I attached it into my Aluminium box and made sure all connections had heat shrinked tube on them to prevent short circuiting. I then attached the solar panel to the circuit. I made the LED stick out of the box and the stayed there with hot glue. The solar panel was stuck onto the box with silicon.
The light now works as it should.


This process was completed in the given time frame

Chirag =)