Board Connection

Making sure to orient the Circuit Playground board with the USB jack pointed "north" and with the TFT Gizmo's 12 o'clock marking also pointed "north", place the battery between the boards as shown. You can use a small bit of blue tack or thin double sided tape to keep the battery from wiggling around.

Also make sure the battery is oriented so the JST cable can plug into the Circuit Playground battery connector.

Screw the 12 M3 screws into the standoffs to connect the boards both electrically and mechanically.

Charging

To charge the LiPoly battery, you'll need to unplug it from the Circuit Playground and into a LiPo charger.

Template

First, print out the linked .pdf template file and cut it out carefully with a craft knife or scissors.

Be sure to print it at a full scale 1:1 ratio -- don't let your printer driver interface scale it to fit!

Foam Cutouts

Now, use the template to transfer the design to the foam sheet with a marker, then cut it out.

Foam Connections

Yes, it's true, we'll need to unscrew the screws we had used during board testing in order to assemble the foam backing. Sorry about that, but it was necessary to make sure everything was working in the hardware/software realm before doing the crafting portion of the project!

Re-assemble the boards with the foam backing covering the Circuit Playground side of the board as shown -- the TFT Gizmo is on the other side, face down on the workbench in this photo, with the 12 o'clock label facing "north".

Top Foam Molding

Just like forming fondant on a cake, we now get to mold the top foam over the Gizmo! The EVA foam is fairly pliable and will conform to a shape when pressed and worked into it.

Center the cutout circle over the TFT display, then work the sides down over the boards.

If you need to get even more forming action you can apply heat from a heat gun or hair drier, but I didn't find this to be necessary in this case.

String Wrap

To better secure the foam top material, as well as to tie/clasp the device to your head later, we'll use about a 6 foot (about 1.8 meter) length of paracord or string as shown.

Wrap the center of the string under and around the boards, then wind them a few times around each other. Pull them tight and then weave them through the holes as shown.

A few dabs of CA glue can help keep the cord twists together where they overlap, although this is optional since the tension applied by wearing the headband will keep it together.

Finishing Touches

Use a small amount of CA glue to secure the two foam pieces, being sure to leave a space unglued for USB cable to plug in from the top.

You can use some clothespins to clamp the parts while the glue dries.

Optional Clasp

You can simply tie the string around your head when you are ready to wear it, or add some fancy plastic paracord buckles as shown here.

Plug the NeoPixel Strip into the JST plug on the side of the TFT Gizmo that is labeled A2.

The A2 port is on the left side of the TFT Gizmo when looking at the display.

It's simple to cut a small slit in a Santa hat to hide the strip behind the faux fur -- which acts as a great diffuser!