LED and Ultra EL Wire Shirt



Decisions, decisions.......

I decided to make a suit that combined LED lighting and EL wire. 

I couldn't decide if this would be for me (again) or for sale. 

And so as I embarked on this project, I decided to create something to my highest level of quality - to keep my options open.

If you want to see the completed video, scroll to the bottom of this post.

Ultra EL Wire

I had read about a new type of EL Wire that contained a stronger core wire. 

This meant that breakages when wearing the costume at a busy event were less likely. 

This item is called Ultra EL Wire and details of it can be seen here

As soon as it arrived, I knew it was ideal for wearable use as it would be less likely to break whilst out and about.

Its stunningly bright too.

I ordered 3 meters of Tron blue, 3 meters of red and 3 meters of gold.

The LEDs

The LEDs are SMD 5050 RGB and came as linked pads with each pad containing an array of 4 LEDS.  I also had some pads of 3 left from the LED bar sign.

I chose to use a total of 38 LEDs which I hoped would not drain the battery too quickly.  I know that flashing the LEDs is kinder to the battery and that static bright is worse. 

Good job I like them flashing then!

Base Layer

I bought a black linen shirt for the base layer.  Once loaded with electronics it would not be washed and so I will only wear this out with a T-shirt underneath.

Here is the wire, LEDs and shirt being tested: 

I decided to separate the LED pads to space them round the shirt more which meant that the wires had to be extended.  There are 4 wires that link each pad.  Red, blue and green for the colours and yellow (or black) for the common +12v return.

Here are the LED positions I chose along with how to wire them all together:

Soldering

There are around 120 solder joints for the LEDs alone.  Each joint is covered in heat shrink to prevent shorts and then the 4 wires are wrapped with insulation tape to help prevent them pulling apart when moving.

The wires are on the inside of the shirt.  Later I used black cotton thread to sew them down.

Controller

To control the lights I designed and made a new controller. 

Here is the project box with the cut-outs:

And with the switches fitted:

The white LED switch block allows me to select from 20 pre-set colours or 20 pre-set fades / flashes. I can also change the brightness and speed of these. 

In short, these controllers are AMAZING!

With the wires fitted inside, there is only just enough room:

The toggle switch provides power to the LEDs and the red button is for momentary power to the LEDs.  However, when power is supplied, it takes about half a second for the LEDs to light.  So flashing them manually in time with the music is not really possible.

The 3 black momentary buttons are for the EL Wire channels.  These are instant and make it easy to flash in time with the music.



Wiring Diagrams

For the whole shirt:

For the controller:

 For the distribution box:

And here are the pin-out colours:Connection System

I used a 12 core cable

And a 15 way HD D type connector:

The distribution box was used to connect everything up:

EL Wire

Having finally completed the LEDs and the control system, it was time to start attaching the EL Wire.

I rough positioned each wire in turn with tape and then took to sewing it all on.

Completion Photos

How the system works

The battery power is split into 2 separate supplies.

One supply is for the LEDs and one for the EL Wire driver. 

From there the two systems are independent.



All of the above is hidden in a bum bag under the shirt.

I will be wearing this shirt on NYE 2015 and following that, will probably put the shirt up for sale in 2016.

Now for the video.........

 

Happy New Year!

UPDATE....... Happy to announce this has SOLD.

Frog xx

Freds Jacket

This jacket was made for my mate Fred.

The EL panels came in the post as a fully wired ready to go kit including driver and battery pack.

 Fred donated the jacket.  In an 80's inspired electric blue colour handmade somewhere exotic.

 

I still prefer to solder all my connections.

And sew all the exposed wires.

This suit takes 8 AA batteries.  I think there is capacity for more panels in the future and the driver even contains a flashing Fred function!

  All wires are within the suit lining.  A hidden hole allows secret access.

  Matching cuffs and collars.

Coming soon to an event near me........

Cheers,

Frog xx.

LED Bar Sign

I was asked to make a light up bar sign.

So I did.

Here is a video of the LED items that I got.......

I'd not used these before and so had a little play with them.

I got two mini controllers, some RGB SMD5050 strips and some RGB SMD5050 pads.

Then using an old cabinet door, I planned the LED quantities I needed:

Dry fitting with masking tape:

Drilling holes to tuck the linking wires into:

Dark test:

Spot of paint.  For this I stuck little round stickers on each LED, sprayed the whole thing and then pulled the stickers off the LEDs:

Finished:.

Things you may be interest in:

1) I used 2 controllers.  One for the border and one for the BAR letters.
2) I reversed two of the coloured wires for the A.  This made the green and blue opposite which make me look quite clever.  In the photo above, all 3 are red as no green and blue are used.


Here is a video of the completed sign working:

The sign ran on a propriety 12v transformer, directly from a 240v supply.  The back was covered to hide all the wires and it was hung above the bar at Glastonbury for all to see.  I installed it Wednesday lunchtime and removed it Monday afternoon meaning that the LEDs ran non-stop for 6 days.

Working with these LEDs was easy and now I know how good these mini controllers are, I will definitely be getting some more.

I want a costume of LEDs but am concerned that too many will be too bright to look at and so I'm currently designing a costume that will have a mixture of EL wire and LEDs.

Cheers for now,

Frog xx.

Fez Time

This week its Halloween and so that means dressing up time.

As I’m heading out to 2 dance events, I decided that my fez needed EL Wire to compliment this EL T-Shirt

The shirt already has a spare connector feeding one of the channels to the neck.

First up was to attach a connector to the length off-cut green 3.2 dia wire.

There are methods on the internet of how to do this.  But for the record, here is what I do.......

• Strip the outer sleeve and exposing the 2 corona wires.
• Wrap copper tape round the remaining outer jacket.
• Stick the corona wires between the copper tape layers.
• Trim the core wire and add solder to the core wire and the copper tape.
• Prepare wires of suitable length for soldering.
• solder the core wire and enclose with heat shrink.
• Second wire soldered to copper tape.
• Lots of heat shrink jackets to keep insulated and add strength.
• Ensure the EL wire works at each stage.

The key thing is to ensure that the core wires cannot touch the corona wires as this causes a short and kills the light.

I was not bothered about the looks of this connection as it will be hidden under the hat...

Position the wire with masking tape...

Select the biggest needle you can find and sew on with fishing wire...

 Finished...

 See you all on Halloween...

Add a spot of face paint. The diagonal EL Wire inspired a few lines on the face. 

 

Apparently people found it difficult to focus on my face. 

 

Frog xx