1. Build the Baffles

Measure the distance between the LED display board and the case glass. Cut 30 strips of A4 Black cardboard to the dimension of that distance.

2. Cut slots into the Baffles

Stack the strips of cardboard into a flat bundle and use tape to hold them together firmly.

Carefully mark the distance between each square on the top of the bundle. When marked correctly there should be 14 marks with the distance between them aligning to the LED panel.

Using a Band Saw or a Junior Hacksaw cut into the bundle 50% of the way through the mark as per the diagram.

3. Assemble the Baffles

Carefully dismantle the bundle and systematically assemble the Baffles as per the pictures. Trim the width of the baffles to fit into the box and ensure there is enough clearance on all sides. For the name TEXT cells remove the baffles as per the picture to ensure that they are not visible when illuminated behind the name TEXT.

4. Glue the Baffles onto tracing paper

The baffles are glued directly onto an A4 sheet of tracing paper over a stencil. Use five minute two part epoxy glue. Smear on baffle edges and hold in place over tracing paper until glue dries. This ensures the baffles are rigid and ensures that there is no light escaping between each cell when a LED lights.

5. Assemble the Word Clock Display

Using the template provided modify the text as required and get three black transparencies printed to the correct size. Get them printed in reverse so that when pushed against the glass the toner side is facing away from the glass. This gives a deeper black on the front display. I went to a local print shop and had this done in one of their colour laser printers which cost less than $4. My advice is to get about 9 copies in case you damage or make mistakes when cutting.

Cut the three sheets to fit the front panel of the box. trim the second and third layer progressively smaller so you can tape them down on top of each other once they are perfectly aligned.

Ensure you leave two sides open so that you can slide a square of tracing paper between the first and second layer of the transparencies.

Finally take the tracing paper that is glued to the baffles and trim to fit on top of the transparencies.

Carefully align the baffles on top of the transparencies tape into position making sure all letters have no obstructions or overlap. Hold up to the light to double check any issues and shake out any loose material.