Now that all of your LEDs are soldered together, take them out of the 4mm price and lay them aside. Take one of your 2mm pieces and clamp it to the back of a 4mm piece but do NOT glue it. With the pieces firmly clamped, sand the edges until they are flat and smooth using your dremel tool or sand paper.
Once the edges are sanded, you can also sand and/or bevel the edges around the holes. To bevel them, take a large drill bit and using your hand, gently twist it on the front of the hole so that it takes the edge off but doesn't dig into the hole and start making it wider. Use your Xacto to clean out the inside of the holes if there are any little pieces of plastic floating around in there.
Repeat for the other peg enclosure. |