How to Build an Arc Reactor Mark VI

This tutorial will show you how to build a Mark VI arc reactor prop. This prop will also be able to fit inside a custom Iron man suit. Specs for that will be introduced at a later date. 

Here is a list of parts and tools you will need for this project: 
Parts: 
1. 1/4 in Plexi-glass 
2. 2 in PVC cap
3. LED Light Board
4. 1/16 in plexi-glass
5. Single ply cardboard
5. Black Spray paint or paint
6. 9V Battery Connector
7. 8 feet wire (Standard red and black)
8. scotch tape

Tools:
1. Drill 
2. Xacto knife 
3. Basic Tool set
4. Hot Glue gun
5. Saw

Here is a template for the internal design. you will need only one copy of this for later. Thank you Mastermind for the template. 

First, look at the PVC cap and find the center of it. Then, Drill an eighth of an inch hole to feed the wires for the LED board. 

Now, take the 8 feet of red and black wire and feed it through the hole you just made from the closed side. Then, strip a half inch of insulation off of both sets of wires (the set on the board and the set that was just fed through the hole). Connect the wires according to color and use electrical tape to cover up any exposed areas. 

TEST
1. test the LED board before securing it. connect the board to the battery case and insert the battery. 
2. If you have issues with that refer to step 10 for detailed instructions on how to connect the wires to the case. 
3. if all goes well the board should light up and you can proceed. If not, check connections and test again. 
4. BE SURE TO REMOVE BATTERY BEFORE CONTINUING!!!

Next leave two inches of wire inside the cap and secure the board down with the hot glue. 

BE SURE NOT TO TOUCH THE LED CONNECTIONS WITH THE HOT GUN BECAUSE IT COULD SHORT THE LIGHT OUT. 

CAUTION WHEN USING THE SAW TO CUT. Be sure to wear safety goggles when cutting. 

After you have secured the LED board it is time to cut the PVC pipe and secure it. you will want to obtain a 1 3/4 inch by 1/4 inch in length. try to keep it as square as possible!

Now, place it inside the cap but DO NOT SECURE IT just yet. 

For this part you will want to cut three disks from a 1/4 in plexiglass. Make sure the disks are the same diameter as the inner diameter of the cap.

Depending on the intensity of your LED board you might want to add scotch tape to one side of the glass to disperse the light for better effect. 

Secure the first disk with glue on both sides of the disk. This should secure the inner PVC pipe also. 

Cut out the template from step two on single ply cardboard. I found that this was easiest with an Xacto knife set as shown. I got this one for 20 bucks at Walmart. 

Once you have it all cut out place it inside the cap and try to center it as much as possible. Now take the second plexiglass disk and place it on top of the template and secure it with glue. 

you will want to obtain another 1 3/4 inch by 1/4 inch in length. Try to keep it as square as possible! This time go ahead and secure it down with glue and at this point double check all the pieces are at the place you want them to be and secured. 

Once you have double checked everything you are ready to cut the second template onto one ply cardboard. Next, take the other two plexiglass disks you cut and sandwich the template in between them and secure in the cap with glue. 

If you notice that there is space leftover inside the cap follow the following steps: 
1. cut one more disk out of plexiglass but this time make sure the diameter is the same as the outside diameter of the cap. 
2. cut out another template two onto one ply cardboard and tape it to the back of the disk you just made. 
3. secure the disk with glue and make the top of the cap air tight. 

Now to move on to the battery connection and testing.

Notice on the battery case you want one that has an on/off switch so it is more convenient then pulling the battery out every time.

Look at the back of the cap. If you see a lot of movement with the wire secure it with glue until it is immobilized. Then cut the other side of the wire to desired length. Strip a quarter inch off the end of both sets of wires (battery connector unit and the red and black wire set from the cap). Connect the wires matching the colors once again and covering up any exposed wire. 

Now connect the 9 volt battery and test again.  

Here is the finished product.