Cutting PCB requires shark cutters and good eye protection. This is best done by an older maker. Please be careful.

Split Mask

Make sure to split the Monster M4sk in a well ventilated area.

I used a set of panavises to hold the board and then aligned a pair of flush cutters along the perforations on the board near the nose bridge. 

Start by cutting the four ends of the perforation and then go back to finish cutting the remaining edges.

Again, you’ll want to do this in a well ventilated area to avoid breathing in any dust and debris.

Connect board

Now we can plug in the Monster M4sk cable.

Each PCB has a connector for plugging in the cable.

Bring the two boards close together and carefully shape the wire so it coils to one of the boards.

 

Mount boards

Align the two board in the enclosure. 

Four M3 x 5mm nylon screws help to mount the board on the standoffs on the 3D printed housing.

The battery is adhered to the back of the board with a small piece of foam tape. 

Glue 

We used glue to attach the whites of the eyes to the enclosure. Apply a small amount of glue to the part and carefully align to the screen cutouts.

Prep Hat

We can optionally remove the attached Cappy eyes to make sewing the enclosure easier.

We were pretty careful and tried not to cut any of the threads.

The 3D printed case is big enough to cover up any glue stains or strands of thread.

I started by carefully peeling back the eyes and then used the Adafruit Craft Knife with Ceramic Blade to cut the glue away from the hat.

Once removed we'll align the sewing tabs on the enclosure over the hat.

Sew tabs

Position the sew tabs close to the hat.

We used a needle and thread to make a running stitch. Attaching the case with thread allows a bit of flexibility it can run along the shape of the hat.

 

Complete!

And there you have it! That's how you can make Mario’s Cappy with animated eyes!

If you have any projects you’d like to share, we invite you to come on Adafruit’s Show and Tell live stream. Attendees get a free vinyl sticker. Also be sure to join Adafruit’s Discord server and become apart of the community!

This guide was first published on Oct 01, 2019. It was last updated on Oct 01, 2019.

This page (Assembly) was last updated on Oct 30, 2020.

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