Objective 4:
Assemble your Chaos Dectector

Cadet, with the TEG fully attached to the circuit board, your final task is to assemble the Chaos Dectector. First, ya gonna cut out an opening in the sweatband to insert the circuit board and TEG. Then, you’ll use silicone sealant around the edges of the TEG to close up the opening and secure it to the sweatband.

 

Let’s finish this!

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1. It’s arts and crafts time Cadet! Take out the sweatband, a pair of scissors, the silicone sealant and spreader, and the combined TEG and Chaos Dectector circuit board.

2. Place the TEG on top of the sweatband, and center it. Using the TEG as a guide, with a pair of scissors, ONLY cut out the top layer of the sweatband. The cutout should be about the size of the TEG, so that fits the TEG. Avoid making the cutout too large. The TEG is 4cm by 4cm, so a side length for the cutout between 3.5cm and 4cm is recommended. Use a ruler to help you.

3. Once the opening is made, stuff the circuit board into the sweatband as far as possible with the LED side facing up. The wires should be stuffed into the sweatband like a Thanksgiving turkey, and the TEG should be right in the place of the opening.

4. Now lift up the edges of the sweatband’s cutout and cover over the edges of the TEG. Lift up each edge and use the spreader to apply silicone to each of the three sides of the TEG that do not have wires coming out. Don’t be shy cadet, add a good amount of silicone.

5. Once the silicone is applied, pinch the sweatband around the sides of the TEG, so that the edges near the cutout is leveled with the top surface of the TEG. Use the spreader to remove any excess silicone near the edges of the TEG. Then let it dry for 2 hours in an open area.

6. Use the spreader to scrape any silicone that got on the surface of the TEG.

7. Then for the 4th side of the TEG, apply a generous amount of silicone and press the edge of the band down into the silicone. Again, use the spreader to remove any excess silicone. Then let it dry for 2 hours in an open area.

8. Again, use the spreader to scrape any silicone that got on the surface of the TEG.

9. Now flip the band inside-out so that the bottom layer of the band is now facing outward. With scissors, cut out the back side of the TEG so that it is completely exposed. It is helpful to start cutting in the middle of the TEG, and then cut up to each edge, but be careful to not over cut. If you do over cut, it ain’t the end of the world. You can fill it in with silicone.

10. Once most of the backside of the TEG is exposed, give it a little haircut by trimming down the TEG's edges that are connected to the sweatband. Make them as flat as possible to the surface of the TEG. It is desirable to remove any excess silicone or sweatband material that covers the surface of the TEG. If you find that the sweatband is tearing off or is not fully attached to the edges of the TEG, add more silicone, let it dry for 2 hours in an open area, and trim again. Repeat this as much as needed. Do this to both sides of the TEG. Once all of the edges are touched up, let everything dry for a full day.

11. After the band is finished drying, decide where you want the LED to be and pop that thing out with extreme force. It is recommended to have it on the opposite side as the TEG.