Fig. E: PMP with plexiglass face. Make sure the PMP
fits in the cavity easily with the plexiglass. Fig. F: Test
the alarm components before securing them with
Fig. G: Audible alarm schematic. Fig. H: The switch
should be seated so it sits almost flush with the heel,
with the button sticking out slightly.
so your PMP will need to rest at an angle.
4a. Line the hollowed-out heel with ShapeLock, allowing enough space to insert the PMP template block.
While the ShapeLock is still soft, place the wood block
flush with the foot bed and heel (Figure C). It may take
a few tries to get the right angle. If it doesn’t work,
remelt the ShapeLock and try again.
4b. Allow the ShapeLock to harden completely,
and then remove it and the aluminum foil from the
shoe. Hardened ShapeLock will not bond with any
fresh ShapeLock or with the shoe, so melt the outer
layer with a hair dryer and then place it back in the
heel to bond with the shoe. Tiny gaps can be filled
in later. With the hair dryer, melt the outer layer of
ShapeLock and fill in the rest of the heel, heating
and cooling as needed.
4c. Repeat with the alarm shoe. The placement of
the alarm template is not as critical as the placement of the PMP, since leather will cover the entire
speaker. Just make sure that you leave enough
room for the ShapeLock to have a minimum of 1"
thickness, and that it’s not sticking out from the
heel or foot bed.
4d. Double-check your heel measurements, making
sure that both are even, and that the heel dimensions
have not changed. Melt more ShapeLock as needed
to fill in any gaps, and heat the hardened ShapeLock
before applying new ShapeLock. For a final shaping,
place a metal spoon in the saucepan to heat up. Use
the hair dryer to heat the ShapeLock, then use the
heated spoon to smooth it (Figure D). With a screwdriver or knife, remove the balsa blocks from the heels.
5. Install the PMP.
Cut a piece of 1" plexiglass to cover the face of
your PMP (Figure E). Make sure the player fits
in the ShapeLock heel with the 1" plexi. This may
require some sanding. If needed, use a Dremel at
low speeds to remove excess ShapeLock. If it gets
too soft during sanding, put the shoe in the freezer
to harden it between sandings.
6. Install the audible alarm system.
6a. Dip the alarm circuit in rubber cement or rubberized glue to protect the circuit. Once dry, arrange the
speaker, circuit, and battery in the heel (Figure F),
and mark an area to drill a hole for the switch on
the opposite side. Make sure the drilled hole won’t
interfere with the circuit board or speaker.
6b. Drill a hole through the ShapeLock large enough
for the diameter of the switch. Using a Dremel tool,
mill out enough room for the top of the switch to
150 Make: Volume 12