Install female headers to the Adafruit Feather M4 Express so they're soldered on the top side of the board. Then, solder male headers to the Adafruit PropMaker FeatherWing so they're soldered to the bottom of the PCB. Test the setup by installing the PropMaker on top of the Feather M4 Express.
Get the pmkb-can-cover and pmkb-can parts and line them up together. Snap fit the cover into the bottom opening of the can. The tolerances are very tight, so I used the surface of the table to force the cover into the can.
Use four M2.5 x 8mm flat head machine screws to secure the Adafruit Feather M4 to the PCB mount. Place the Feather PCB over the standoffs and line up the mounting holes. Insert and fasten the machine screws to secure. Once fully tightened, snap-on the Prop-Maker FeatherWing so the headers are fully seated.
The 3-pin JST cable from the NeoPixel ring will need to pass through the bottom of the PCB mount. Insert the connector through the side and out the bottom like shown in the photo. This will make installing the components into the can easier.
With the wiring setup, start inserting the NeoPixel ring through the top opening of the can. Carefully push the PCB through the can so it's over the bottom cover. Using your fingers and orient the PCB so the wiring is not tangled up. The NeoPixel PCB is press fitted into the bottom cover. Little nubs on the inner wall will catch the edge of the PCB so it's secured in place with a friction fit.
Grab the wired toggle switch and begin to plug it in. Connect the 2-pin JST cable into the battery port on the Adafruit Feather. The Feather PCB stack should still be outside the can with the 3-pin JST wire still coming out the bottom.
Go ahead and grab the 3-pin JST cable (the male one wired to the NeoPixel ring) and plug it into the NeoPixel port on the side of the Prop-Maker FeatherWing.
Take a moment to install the speaker into the cap. The inner walls of the cap have two little nubs that will catch the outer ring of the speaker metal housing. Press fit the speaker so it clicks into place. Insert at an angle to get the ring through the first bump.
NeoPixel Wire Install
Grab the female 3-pin JST cable and thread it through the opening on the side of the can. Pull it through and begin to work the PCB mount into the can. You'll want to make sure the Feather's USB port is facing towards the circular opening – This will make it easier to access for recharging the battery or reprogramming.
With the PCB mount inside the can, take a moment to orient the components so the wiring is manageable. You'll need to grab the PCB mount and line it up with the two mounting holes. While holding the part in place, insert and fasten two M3 x 6mm to secure the PCB mount to the can. Carefully pull the switch out of the can, through the center of the NeoPixel ring. The switch and JST connector should be protruding from the bottom. Grab the 2200mAh battery and connect it to the JST port on the switch. Flip it on and off to test the circuit. The NeoPixel ring should light up (code should be already uploaded).
The blade decals were glued using E6000 adhesive. I used a fine tip (like a syringe) to apply the glue. Allow the glue to set and dry before proceeding with the assembly. When it's ready, get the wired NeoPixel strip.
Insert the 3-pin JST cable through the bottom opening of the blade. Push the NeoPixel strip through and get the JST cable to come out of the side opening. I used a pair tweezers to grab hold of the connect and pulled it out the side. I used a spudger tool to line the NeoPixel ring with the back wall of the blade – The further away the light source is from serrated teeth, more diffused the effect will look. The tolerances are fairly tight inside the blade, so it has a friction hold. Optionally could use double-sided tape to secure the strip. Test the blade by plugging in the male JST cable to the female one from the NeoPixel ring.
Install Speaker Cap
Now is a good time to close the top of the can. Grab the cap part with the speaker installed and press fit it over the top opening. This has a twist locking mechanism. Line up the nubs so the speaker cap press fits and twist to lock it in place.
Grab the blade with one hand and the can with the other. Position the blade and the can so they're in the correct orientation. In order for the blade to snap fit, you'll need to apply pressure over the Feather PCB. I suggest temporarily removing the Prop-Maker FeatherWing and using your two index fingers to snap the blade into the can. Start with one side first then get the second to click into place. Use your thumbs to keep the two parts together, it'll help stabilize whole build. Be careful handling the blade and do not grab hold of the serrated teeth – they can hurt you so please be very careful!
NeoPixel Blade Power Test
With the blade installed, it's a good idea to test the circuit again to check all the components are still working. Now is a good time to take a moment to organize the wiring or reduce any of the wire lengths.
Get the pmkb-coupler and pmkb-pipe-neck parts together. Use three M3 x 8mm pan head machine screws to secure the coupler to the pipe. Place the coupler over the flange on the bottom of the pipe. Line up the mounting holes. Start by fastening the top screw through the coupler and hose.
Grab the blade assembly and place the pipe next to it. Position the two assemblies so they're in the correct orientation. The inner diameter of the piping is designed to snuggly fit the 2200mAh battery. Begin to insert the 2200mAh battery through the piping and pull it out to test the tolerances. If it's effortless to get in and out, you can safely push it down all the way through.
Install Toggle Switch
The toggle switch is panel mounted to the side of the coupler – There's a opening on the side thats sized to fit the threaded stem on the switch. Use the included hardware to secure the toggle switch to the coupler. Fasten the hex nut using pair of vise grips so it's tightly secured to the side of the coupler.
Now it's time to get the two main assemblies. The top of the couple snap fits and locks onto the bottom cover of the can. Before the two can be connected, the wiring needs to be fitted inside the assembly. There should be room in the couple and down the pipe for any access wires.
Insert the coupler at an angle so the semicircle is seated first, then work the next of the tabs through the bottom cover. Apply firm pressure to the parts to snap fit them together.
The handle screws onto the pmkb-tube part. These have screw-threaded ends that twist together. The pmkb-pipe-extender part is next, twist that onto the pmkb-tube part. Lastly, screw the pipe extender into the end of the pipe with the blade.