My previous effort, which worked very well, had a significant flaw: exposed wires. It was too easy to catch the wires on things, and eventually I ripped the legs off one of the LEDs. Therefore, I decided to add PVC piping on either side to contain all the electrical components.
I exchanged the 1.25 x 1/2 PVC bushings for 1.25 x 3/4 bushings, and used two elbows, two tees, and pipe of that size on either side. A bit excessive, but it ensured that there would be enough space inside for stuffing lengths of wire. You HAVE to thread the wire through all the PVC pipe and fittings first, and have enough extra wire sticking out to allow you to do any soldering necessary.
I used the same types of LEDs and detectors as before, but this time I used 1" x 1/4" nylon flat washers (metal ones work just as well), with LED holders placed inside. Once you place the LEDs inside, they'll stay put.
Here's the view of the LED from the front.
I placed each emitter and detector inside a PVC bushing, and used a small ring of 3/4 PVC to press them against the ridges inside the bushings. Now hook up the electronics as before, and voila!
With so much more of the wires and parts contained, this is actually more mobile, in my opinion, and easier to move. Hook it up to a tablet, and it would probably be useful to take to wars.
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