
Return
Week 5 now. I feel like this semester is flying by pretty quickly.
After sleeping on it for the weekend, I have come back to realize I still don’t want to deal with the LEDs and cables right now.
A Splash of Color
Instead, I’ve decided to finally get on with painting the XPS foam. Shortly after I published my blog last Friday, my friend provided me with some paints to borrow. I took some time to mess around with them on a test piece of XPS foam.

On the bottom right is a primer made from mixing black and some Mod Podge, painted with a mix of brown and white on top. On the top left is black painted straight onto the foam, which did not work very well at all.
Despite leaving the primer to dry overnight before painting the brown on top of it, which was left to dry over the weekend, the brown paint still feels wet and comes off just by pressing my finger to it. This is the most experience I’ve gotten painting like this, so I’m not really sure what the issue is or how to solve it.
I followed this Reddit post which, while it doesn’t apply to my situation exactly, does give some seemingly good ideas on what I can do to improve my situation.
One user states that Mod Podge is supposed to “dry clear”, and to apply a layer of it before applying a separate primer. However, another user in this Reddit thread states that black paint with Mod Podge is a good sealant and primer.
The common theme between the posts is mentions of keeping the primer layer thin, so I believe my idea was correct, but my process needs to be improved.
So I brought out the Mod Podge and paint and tried again. I applied some Podge with a wooden stick, threw some black paint on to it, and kept mixing and adding Podge to try and get a dark grey color.



I tried spreading the layer as thin as I could, but I definitely used WAY too much black paint. Even in person, the color is still just straight black, not dark gray. I didn’t want to keep adding more Modge Podge because I was worried I wouldn’t be able to keep the layer thin, and because it would cover the whole board.
I’m almost certain that this won’t work, and I’ll need to adjust my mixture of Podge and paint, but we can only wait to see.
In the meantime…
Solving the LED Conundrum
One of the last things I had talked about in my last post was how I could store the LED lights in the swords so that they could be replaced but also would stay in place securely.
I talked to Shannon and Cartland about my ideas and we came to the conclusion that it’s worth at least trying to design a casing for the LED before tearing the original casing apart.
I tried looking up the part to see if I could find literally any more information about it, and to see if someone already created the part to save me some work.
I checked a few Lego part websites but none of them had a listing for any components of the Inika swords. Bricklink did have one custom listing for the transparent tube that goes into the swords, but there was no other information I could find.
I also checked various 3D printing websites for a model of the LED casing, but despite this model giving me some hope, I was unable to find anything. Which is, unfortunately, not a surprise to me, given how complicated the swords are, and also with how little love the Inika get in favor of the 2001-2003 years of Bionicle.
So with that said, it’s time to get to work.
Micro-Measurementing
I grabbed the two LED blocks that I had removed from Jaller and Hewkii, along with the extra sword that both Hahli and Matoro had in their canisters. My plan is to get some measurements from the blocks and the sword compartment itself using a micrometer.

I opened up Matoro’s sword to prepare to measure, but quickly started seeing some major issues. The screws were massively stripped and seemed to be covered in a bit of rust and corrosion. The transparent tube is also extremely dirty, and the silver plastic all around the sword has signs of animal biting. I imagine the only reason this ended up in the canister is because I have no other duplicates of the sword.
But that’s not all. After taking off the battery cover…

The compartment is infested with some horrible corrosion! In a dark brown coloration no less, which I don’t believe I’ve seen before!
Despite my aversion to damage or modify the original components, I can make an exception when it’s for the sake of preservation. It just so happens to be that this will provide a great look at the inner workings of this little block.
It’s time for some emergency…
SURGERY
For this procedure, I’ll need the soldering tools provided in the DKC. Thankfully, one of my favorite hobbies is repairing electronics, so I already have a good amount of experience with soldering. It’s been a minute since I’ve done it though, so I’m a little nervous.
However, this procedure is very exceedingly simple:

The goal is to remove the green motherboard from the black plastic that houses the LED.
The four silver points are solder joints that connect wires to the board, which will carry electrical current. The two in the middle correspond to the LED’s anode and cathode, while the two on the corners connect the coil that siphons electricity from the batteries.
To remove these joints, it is as simple as heating them up to their melting point so that they stick to the soldering iron and come off of the board. The biggest danger here is just the potential of burning myself (and also partially the evaporated fumes of whatever type of flux was used to create these joints (and also maybe the battery corrosion itself, I’m not sure if heating it up will cause it to also evaporate or react in some way that can harm my body)).
Of course, we must take proper caution when working with solder. I’ve opted to wear a face mask to avoid breathing any of the potential fumes created by this. The DKC is plenty spacious and well-ventilated though, so I don’t worry too much.
With the tools in place, it’s time to glove up for the operation.

After a good hour of persuading, finessing, and fangdangling, it eventually comes off.


Now, as much as I’d like to call it a a complete success, there were some complications.
Plastic’s melting point is about 400 degrees Farenheight. It is unfortunately also the melting point of solder.
While I tried to avoid touching the plastic with the soldering iron directly, the prolonged heat, on top of the metal clip also absorbing heat wildly, meant that the plastic did start to reach the melting point. Pictured here are the teeth marks of the metal clip, melted into the casing.
Furthermore, I also absolutely drenched the board in flux. It is harmless, but I made quite a mess.

Regardless though, the separation was a success, so now it’s time to do some maintenence.
For cleaning, I went with the ol’ cotton swab and a bit of alcohol… and also some isopropyl alcohol to dab them in. It cleaned off the nasty corrosion real good. There were some spots on the block that the q-tips couldn’t quite reach, but for that I just submerged it in some alcohol which should clean up most of it.
While it’s cleaning, this gives me a good chance to talk about my findings.
First, the LED that was in the block is almost certainly unrecoverable- or if it is, it’s going to be a lot more difficult than to just put a new one in.

While removing it from the block, I noticed that I had a bit of trouble. I had assumed that it was due to the corrosion sticking it in place, but I was mistaken. The LED is held in place the same way the block is in the sword; with some light pressure fitting along some clips.
Replicating that with a 3D print is going to be very difficult, so I may opt to change the design a bit when I finally create my model of the block. I’m not currently sure how I’ll go about it, but I know I’ll figure it out.
Back to Schedule
For now, I’ll hold off on putting the block back together as I may end up needing to take a peek at its components individually. I won’t be able to use it for measurements though, because of the deformities it gained during the operation.
Immediately Off Schedule
Not long after finishing the last section there, the campus was hit by a winter storm and got closed for two days. This ideally won’t really affect the hours I put into the project this week, but it does make things a bit stressful.
Regardless, after returning back I immediately went to check the paint on the XPS board. Unfortunately, while the primer I created is dry from what I can tell, the brown paint I added afterwards is still wet to the touch. I’m not sure what to do about this, as the paint should have dried fully after two full days.
From looking it up, my best guess is that I painted the layer too thick, somehow, or that oil-based paints just aren’t viable to use on XPS boards. I’ll look into picking up some acrylic paint instead and see how well that works.
Finally Measuring This Time, I promise
With that out of the way, I’m going to focus all my efforts on designing a light block to put these LEDs in. There’s been enough distractions.
Using a micrometer, I got a variety of measurements from the light blocks that I would then mark down on a document. From there, I used those measurements to create this prototype model using my rudimentary modelling skills in Blender.

I made sure to use as accurate of measurements as possible, and to set the scale in Blender to work with millimeters, so this should be to scale.
I’ll do test prints until I get the size right, and then modify the actual model if need be from there. I’m really hoping I don’t have to.
It’s worth nothing too that this model does not take into account the circuit board of the original light block. My plan was to leave the bottom open so I can slot the LED in, and then have a separate “lid” that is printed in the shape and dimensions of the circuit board.
Next Steps
That’s all the time I have for this week, so it’s time to discuss the next steps.
First, I am going to stop by a Michael’s and pick up some cheap acrylic paint for the XPS boards. I can’t afford to wait weeks waiting for this oil based paint to dry.
Then on Monday, I have a block of time carved out to use the 3D printer. It’s pretty busy so hopefully I gave myself enough time to properly do some prints on it. Once I have my current model printed out and have the kinks worked out and ready for a final product, I’ll add a modification for a lid so the LED light can be sealed in.
Then once that is done, we can start looking into installing the new LED lights into the Inika and making some modifications to their swords so that I am able to connect the lights to wires.
While that is being done, I want to test out the acrylic paint on the XPS board and see if it is any quicker to dry.
Ideally, we’ll start being able to put the Inika in their final positions and make this thing look like an actual display.