LEDDAR shield

These are my notes for building a protective shield around the LEDDAR One based upon their spec.  I don’t have a complete build yet, but I’ll post a photo when I do.

Components and preparation

Drawings

  • Sticky back paper
  • draw a 60mm diameter circle with a compass – this is the outline of the plates
  • choose 3 points around the edge and draw an arc, 60mm diameter as before – this locates the centre of the circle.
  • from the centre, draw a 45mm diameter circle – the mounting holes lie on this circle
  • choose a point on the 45mm diameter circle, and draw an 38.79mm radius – this identifies the isoceles triangle points for the mounting holes
  • with the 2 new intersects arc 2 more to clearly identify clearly 3 corners to equilateral triangle
  • choose a pair of the equilateral triangle points, and draw a line between them
  • draw a line from the third triangle corner through the centre point of the circles up to the new line to identify the centre of the line – these should cross at 90° if your drawing is accurate
  • From the line between the two triangle corners, draw parallel lines above by 1mm and below by 21mm and 27mm.  These are the centre points for the sensor and the 2 rows of LEDs respectively  .The 6 LEDs are separated horizontally and vertically by 6mm.
  • if you’ve done this correctly, it should look a bit like this:

    LEDDAR cover

    LEDDAR cover

  • carefully cut around the outer circle and stick to the 60mm diameter acrylic discs.

Drilling etc.

  • center-punch all ten marked holes (3 corners, 1 sensor and 6 LEDs)
  • peel off the template and top protective sheet and discard.
  • drill small (1mm) pilot holes through the points of the triangle
  • separate the two disks
  • drill a 2.5mm hole through the bottom plate
  • tap an M3 thread into these bottom plate holes and put aside
  • drill out 3 x 3.2mm holes through the top plate at the 3 corners of the triangle
  • drill a 22mm hole at the sensor center point using a step drill bit set
  • drill 5mm holes for the LEDs
  • file out the LEDs if you wish or need.
  • countersink the triangle holes – do this after the LED holes or drilling the LED holes will slip.

Just FYI, I bought a new Rotring compass, 0.1mm pen, ink and adapter to get this as accurate as possible.

It is possible to get 60mm diameter, 3mm thickness, 10cm tall clear acrylic cylinders / tubes from ebay, to cut to the right height and protect the sides.  I have these on order but have not tried them yet.

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