I thought I'd throw together a quick tutorial on how I built my Young Flynn or Flashback Flynn jacket for Halloween. This post might wind up on a friend's blog, but I thought I'd share it here first and see what everyone thinks.
I chose the Young Flynn style as it was simple to do for a first-timer--straight vertical white illuminated strips on the right outer zipper and the left inner zipper. Wanting to keep this to a budget, I did not opt for the screen-accurate leather motorcycle jacket, but rather picked up a $35 pleather jacket at Burlington Coat Factory that evokes the style. Importantly, it has a thin inner liner that can be used to hide wiring.
Next came the work of sourcing electroluminescent tape for the illuminated strips. Following suggestions, I decided to use LuminousFilm.com, purchasing a strip of their half-inch-wide split electrode POWO (pink off, white on) tape, as well as inverters and ETCO clips (for making electrical contact to the tape). For the purposes of the ensuing photos, I've used 1-inch-wide tape as the half-inch was used up.
EL tape, four ETCO clips, and a 9V inverter with connector and internal battery compartment
Close-up of ETCO clips. Note the teeth that bite into the phosphor layer of the EL tape after crimping.
Connecting to the EL tape was the trickiest part. Conductive glue and staples can work, but there are durability concerns. Using the ETCO clips, I've had no broken connections thus far. I first crimped stranded wire to the clip, soldered it in place, then crimped the wired clip onto the EL tape. I finally wrapped the whole assembly with black electrical tape for added strength, being careful to ensure that the two adjacent ETCO clips don't touch each other (a bit of a challenge with the narrower half-inch tape).
Picture showing how one can crimp the wire to the ETCO clip (I recommend soldering afterwards for added strength) and two ways for crimping the clip to the EL tape.
Regarding inverters, they take 9V or 12V DC from batteries and produce the high-voltage, high-frequency AC required for the EL tape to glow. The inverters are often rated in terms of the area of EL tape (in square inches) that they can drive. The small 9V inverter pictured above can only drive 5-12 square inches, insufficient for the two EL strips on the jacket. I therefore used a
larger 12V inverter that would be up to the task. The electronics are potted in epoxy and there is no battery compartment. I therefore used a 8xAA battery holder with 9V battery clip to produce the proper supply voltage. This arrangement was able to power my jacket for several hours at a Halloween party without problems.
If using more than one strip of EL tape, note that they must be connected in
parallel. With that in mind and the EL tape wired to the inverter and batteries, next came final assembly. To make the design modular, I used self-adhesive Velcro (which is conveniently available in a half-inch width) to attach the EL strips to the jacket. I then cut small holes in the material of the jacket and lining for the wiring. Although not pictured, I used a series of two-pin connectors (commonly available at Radio Shack or online) to make hookup and disassembly simple. I hid the inverter in an inner pocket of the jacket, and then cut holes in the lining so that the 9V clip attaching to the battery holder was accessible from an outer pocket.
Inverter pulled out of its inner-pocket hiding place. The black edge of the Velcro is visible.
Inverter back in its inner pocket, with connector and wiring visible. The wiring disappears into holes in the lining at the lower hem of the jacket.
I did not add a switch to turn the EL tape on and off; one can easily use a thumb to disconnect the 9V clip from the battery pack in the outer pocket.
Here are a couple of pictures of the finished product, ready for the Grid!
Hope that was helpful (even if pic-heavy)!