I decided to stick the battery and Arduino inside the hat, so there’s no protruding bits. Except for weather, there’s nothing wrong with keeping everything on the outside! This makes it easier to show others how it works…and you can further decorate it into a steampunk or cyberpunk aesthetic if you like.
Use the solder joint trick on the “Coiling” page to get it straight!
Using a hobby knife, cut a + shape in the hat, just large enough to push the JST connector through.
I’d previously punched holes through the sleeve for the wires to fit through. Not necessary, just me being OCD-retentive. You can cut a notch or simply pass the wires over the top.
Humans are humid. We all release some amount of water vapor through our skin, even if not damp from exertion. If you’re particularly gifted in this department — nothing wrong with that — you might choose to seal the electronics in a conformal spray coating, rubber spray or even a thick acrylic.
Insert a USB cable and cover the wire ends with tape before doing this. Allow a few hours (or overnight) for the sealant to dry before continuing.
The 3xAA holder now in stock features a push button rather than a switch, in a different corner. You’ll probably want this rotated so the button is out near the perimeter of the hat…less likely to be accidentally toggled by the crown of one’s head.
Here I’ve glued pieces of the “hook” side to the back of the battery cover, the Arduino and Bluetooth module.
Nasty stuff, E6000. Put everything out in the garage and do something else for a couple hours while it dries. Play video games. Go for a walk. Practice your posh accent.
I tacked the wires in a few spots with hot glue, and also used this to hold the block connectors in place. Hot glue usually isn’t favored, but I’m using it here because it’s weak…a dab of rubbing alcohol breaks the bond if needed and the parts and wires can be rearranged and re-glued.
This piece is not glued in place, it’s simply cut a bit larger than the hat and stays in place via friction. It’s easy to peel this back and access the power switch and battery box. And you can replace this if it gets a little funky from sweat, hairspray, etc.