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Arnoldc

Halloween/Christmas poll lights

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John Slade Wrote

Cant wait for the finished product!! I really like how the lower section has a C-9 bulb look to it!! GREAT JOB Arnold!!!!



I hope the C9 part is the TOP or it would be HARD to mount !!!

Looks Great !!!

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The design has a 1/2" pvc pipe that goes in the center of the light, this is part that keeps everything centered but also removable to change the light.. Now, I plan on wrapping minis around that pvc pipe to get the effect.. I could modify it easily to handle a c9 bulb

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Arnoldc wrote:

The design has a 1/2" pvc pipe that goes in the center of the light, this is part that keeps everything centered but also removable to change the light.. Now, I plan on wrapping minis around that pvc pipe to get the effect.. I could modify it easily to handle a c9 bulb

why not put an actual socket in it and use one of those lights that "flicker" like a candle?

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jimswinder wrote:

Arnoldc wrote:
The design has a 1/2" pvc pipe that goes in the center of the light, this is part that keeps everything centered but also removable to change the light.. Now, I plan on wrapping minis around that pvc pipe to get the effect.. I could modify it easily to handle a c9 bulb

why not put an actual socket in it and use one of those lights that "flicker" like a candle?


That would be too easy.

MikeH

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Lol mike is part right. Real reason is I didn't think about that.

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Well this is what it looks like so far.. Tomorrow, light sanding and paint then add the "glass" and waaaalaaaa
However, there is a mold change. I have decided to skip the halves and make them in once piece.. This will eliminate the issues of filling and sanding. Plus it will be a better looking product at the end.


Attached files 250834=13626-Light.JPG

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Arnoldc wrote:

Well this is what it looks like so far.. Tomorrow, light sanding and paint then add the "glass" and waaaalaaaa
However, there is a mold change. I have decided to skip the halves and make them in once piece.. This will eliminate the issues of filling and sanding. Plus it will be a better looking product at the end.




Excellent! Be sure to post a order form as well!:D :D Your gonna be BUSY!!!! LOL

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The prototype is about done, I have some touch up paint to do, plus some more jigs to make.. But this is what it looks like as of now.. Keep in mind I do have a new mold being made as we speak.. So the finish should come out more uniform.


Attached files 250901=13627-light2.JPG

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After leaving the light out in the Texas 105 heat over the weekend I have discovered a few issues. The foam is warping and pulling away from the legs.. Also, my great idea of having the bottom removable, works but doesn't work..
So after some thinking, I have resolved both of these issues. I plan on gluing a 1/8" thick wood plate both under the top (where the light goes) and on top of the bottom (where the light goes)and adding blocks in the corners where the vertical risers go.. All 3 sides will be glued into place and the 4th will be screwed into those blocks. This will do 2 things, one it will eliminate the need for the PVC pipe. So the ones that want to use the c9 bulbs do not have worry about a PVC pipe being in the way and can hide the wire simply by gluing it to the corner blocks. Second, it will guarantee that the light cannot warp, making my life a little easier.. The sub structure I had used on the one above worked great, but it was loose from the bottom.. The new structure everything will be in once piece minus one panel. I'm hoping this will speed up the build time to just an hour per light. (If I sell these they will come top bottom, glass and legs, with directions how to assemble and what paint to use). Now, its just a waiting game til my new molds are ready.

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Thanks guys! Looking forward to getting all the tweaks done so I can start cranking them out! I got another lamp design I'm working on as well. One thing at a time! lol

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The new plugs are in the works. I used plaster to make the new plugs. As you can see by the picture I an blending the 2 pieces so they are one. This is my 3rd go around on this.. Im finding that the dingle berry is somewhat difficult to keep on with plaster.. I will have this completed by tomorrow morning, then time to pour rubber! Hopefully new mold will be in house by Thursday.
I also have all my jigs completed now!


Attached files 252500=13743-IMG00631-20110712-2139.jpg

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Attached is the last light of the "half" version. This one came out a lot better. Tomorrow I will have the new molds so I will start posting pictures of that for now on.
This one I included all the changes as mentioned earlier. There is a 1/8" thick piece of wood on both top and bottom in the inside of the lantern. Then I put wood blocks to accept the legs and glass, also to allow for one face to be removed for light access.


Attached files 252632=13750-IMG00635-20110713-2114.jpg

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And this is what it looks like completed. The face you are looking at is removable, there will be 4 screws holding it in..

On the other good news side is I have my new molds! New pieces to be cast tonight!



Attached files 252687=13756-Light.jpg

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Well.... If I told you guys how much it took to get this one piece... You guys would think I am crazy! I am using a rubber product for the mold instead of the previous silicone. (free, what do you want?) welllllllllllllllllllllll, this you have to use a mold release, which I have, and have been using before.. The neat thing that I didnt KNOW was it takes several layups to get the rubber "proofed". So, the pictures you are seeing is the 4th layup of the night. The older the mold gets, the better the piece will come out.
Also, you guys may get a kick out of this.. I am now putting a lid on the mold, with a hole in the center to release the pressure. I put foil on the lid which is made out of wood (this foam stuff sticks very well to wood, no matter what you do). poured that last layup of the night.. got the lid on... but you hear something.. oh c**p for got to put a hole through the foil.. BAM, got foam all over the place.. oh what a fun evening! lesson learned!




Attached files 252869=13779-IMG00642-20110715-2242.jpg

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and....... here it is.. I still have some learning to do to make this look perfect.. The biggest thing is I need to re work the leg miter jig..


Attached files 252889=13782-IMG00645-20110716-1127.jpg

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Looking Good!

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shfr26 wrote:

Looking Good!

No... Looking great!

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Thanks guys! I'm still having problems with the one piece molds. I will probably go back to the half version. The prep time is less, and the pieces look better In the end.
I think I can hide the seam line/ blend with a flat finish. Will keep on making the one piece version for a bit longer.

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I finally got clean pulls today! I switched to a different mold release agent, and that has done the trick! Now time to start cranking these things out!
Im a very happy camper now!:cool:

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Jeff Millard wrote:

Was trying to make an RGB pixel for these today. I need to order better green LEDs. The only green I had that was diffused is just an indicator and isn't bright enough. I've got some others that are bright but not diffused. I'll try a little sandpaper to see if that helps. I'll make a couple if it turns out OK and ship it out after I fit test it. Will it be easy to open to get a small square circuit board in it?

Jeff
EDIT: Update. I added a picture of some RGB pixels I already had but had forgotten about. This is exactly what I wanted to make. I didn't want to use individual LEDs but I've got them on hand so it's what I'll try. If it looks funky, I'll get some RGB LEDs from eBay and try again.
Jeff-

yes, I tried to design it so everyone can do their modifications to it as fit for their wiring requirements. One whole face is removable. I did try to make it so one can just screw all the legs to the top and bottom and be done with it, the problem is it is difficult to do this and keep square without the jig. So, I went back to that one panel deal. There is a 1" dia hole in the wood (needed it for the jig) in the wood. A quick hit with dremel tool with a cut off wheel will make quick work for whatever you need to do. The wood is only 1/8" thick, and foam from that point in.

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Arnoldc wrote:

I finally got clean pulls today! I switched to a different mold release agent, and that has done the trick! Now time to start cranking these things out!
Im a very happy camper now!:cool:

I fully understand you wanting to make these...and am ENVIOUS that you are able to create these great looking lights...but with all the time, effort and expense you have put into them, wouldn't it have been quicker and cheaper to buy some inexpensive outdoor wall lights from Home Depot??

http://www.homedepot.com/Lighting-Fans-Outdoor-Lighting-Outdoor-Wall-Lighting-Outdoor-Wall-Mount/h_d1/N-5yc1vZbvni/h_d2/Navigation?Ns=P_REP_PRC_MODE|0&storeId=10051&catalogId=10053&langId=-1


Attached files 253232=13821-b850abfc-c541-412b-9f38-adcf91ba6e46_300.jpg

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