The Dongle Kit contains the following:

  ● A 6 cm length of wooden dowelling pre-drilled with 2 mm and 3 mm holes.
  ● Two 20 mm M3 stainless steel bolts.
  ● Two M5 stainless steel nuts.
  ● Six M3 stainless steel nuts.
  ● A wooden cocktail stick.
  ● 3.2 metres of enamelled 0.2 mm diameter copper wire.
  ● A small piece of sandpaper.
  ● 75 cm length of non-stretchable cord.
  ● Two pieces of heat shrink.
 

 

The wire needs to be doubled back on itself and the ends clamped next to each other. Insert a small pin or needle in the loop and stretch the wire a couple of centimetres. This will ensure all the kinks are removed. Then insert the loop in the 2 mm hole at the end of the dowel and secure with a piece of cocktail stick.

Keeping the wire taut, slowly wind the coil until you reach the second 2 mm hole, at which point thread the ends of the wire through the hole and again clamp with a piece of cocktail stick. The holes have been drilled 25 mm apart to ensure there is plenty of wire remaining to make the necessary connections.

 

 

Assemble the bolts as in the photo and trim the wire ends so they can wrap around the bolts a couple of times. Before doing so, sand off the enamel coating to ensure a good electrical contact is made. Be very gentle to avoid snapping the wire.

After wrapping the wire around the bolts, push the bolts through the dowel without turning. Then hold the bolts, again without turning, and secure with the final retaining nut using a 5.5 mm spanner.

If you have a multimeter, you can test the resistance of the Dongle by connecting it to the bolts. The meter should read around 2.3 Ohms.

N.B. Keep an eye on the retaining nuts, as they may work loose over time. If you use heat shrink to protect the coil, it is a good idea to reheat it after a few weeks as the wooden dowel may also shrink.

The following may be useful if you intend making a number of Dongles:

  ● Basic multimeter.
  ● 5.5 mm spanner.
  ● 2 mm Allen key.
  ● Reel of 2 mm (32 AWG) enamelled copper wire.
 

 

If you wish to wear the Dongle around your neck, a non-conductive cord can be attached to the bolts and held in place using pieces of heat shrink tubing, which will be supplied with each kit.

 

 

Remember, we are always happy to help you in any way we can with the assembly of your Dongle. Just send your questions via the Contact page.