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
- 2 60mm diameter, 3mm thick black acrylic disks
- leaving their protective covers in place, stick them together temporarily with some thin double sided tape.
- 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:
- carefully cut around the outer circle and stick to the 60mm diameter acrylic discs.
- 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.
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.