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Project Integration

A project log for Organ-Playing Skeleton

Consumer products merged into a custom display

bryanlowderbryan.lowder 10/28/2023 at 21:450 Comments

We now had a timer, power supply, splitter, controller board, a SKELLY, and a music player. The button on the music player was clipped off and the leads soldered to the control board. The leads were short and the controller had to be physically close to the music player. 

Above, the DEMO button connector pulled out of the back of SKELLY. This sort of keyed two-pin header seems to be pretty commonly used for DEMO switches on consumer products. I happened to have an identical one on short leads that I soldered onto the controller board. 

The music player originally was four components stuck to a big sticker by double-sided foam tape. Once the speaker was clipped and peeled off there was room for the control board, which was also taped onto the big sticker. 

The completed controller/music board looked like this:

This photo is a little visually confusing, but the power connector is at the top, then the black connector on the bottom is just a 1/8-inch audio plug (an AUX cord end), and the little thing obscuring the audio plug is the header connector that plugs into SKELLY.

Note the generous use of hot glue to secure fragile leads. Mechanical robustness is easy to forget in electronics projects. Although hardly an "extreme" environment, there would be stresses, and reliability was important. 

We decided the sticker with control board would be securely taped to the back of SKELLY with double-sided foam tape. This accommodated the short leads to the DEMO connector and was easily hidden by the planned-upon clothing.

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Here one can see the control board + music player taped to the back of SKELLY, along with the battery adapter, the power cord, the organ and a black candlestick. The AUX-style cord is plugged into an extender which went to a much bigger amp than originally planned, improving the volume and bass wonderfully. There is a piece of tape covering the speaker on the back of SKELLY in an attempt to muffle the awful music endemic to the animatronic ("Come on all you ghouls/ Dance around like fools..."). The tape was not effective enough, so MIBRO eventually just opened up SKELLY and cut the wires to the internal speaker.

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