Roof Grids

[nmonkman]

Okay, so I got a lot of requests to post pics of my roof grids. This was a huge learning experience, but I think I worked out all the kinks. My roof consists of 22,000 lights. There are 4 channels of red, 2 channels of blue, 4 green, 4 purple, 4 gold and 3 multi color. It would take me 3-4 days to get the roof done with all that walking up and down and God only knows how many trips up and down the ladder. I calculated it to be 1.8 miles of walking on a 12:1 slope just stringing the lights. That didn't include the trips up and down the ladder. It was quite hard on the legs. Anyway, last year I decided to eliminate the walking by making grids out of 3/4" PVC. The lights are now on there permanently. All I need do this year is pull them out one at a time (check for bad strings) and then pull them up in place. I will have to attach one picture at a time with an explanation of each. I will point out the flaws that had to be fixed after they were made as well with tips and hints.

[nmonkman]

This is a view of them on the ground. NOTE THE CORNER BRACES. I made these too wide and later had to reduce them. I found that 3.5' wide is about the maximum width before they get real "wobbly"

[nmonkman]

This is how I did the bends where they meet the peaks. I used a 45 degree and a straight coupling to make the angle. Even if your roof is not and exact 45, the grey PVC is flexible enough so that it will look straight.

[nmonkman]

This is another view of a braced corner. Note the use of zip ties was my first thought. However I found that they would easily slide. I ended up using 1-5/8" deck screws to attach the lights to. It was a lot of work doing this, but it allows easier replacement of light strings because you don't have to cut any ties, you just unwrap. I found that one single wrap using one of the two wire is sufficient. DO NOT get too carried away with wrapping because you may have to overlap and find yourself with no room.

Edited September 1, 2012 by nmonkman

[nmonkman]

Lastly here is a photo of the in place grid. This gives you a better idea of the minimum bracing required, how the angles look and work, etc. If anyone has questions, let me know. I will try to post a list of do's and don't based on my lessons learned.

Edited September 1, 2012 by nmonkman

[Santas Helper]

_{Wow! that looks impressive. Can't wait to see pics of it lit up.}

Edited September 1, 2012 by Santas Helper

[nmonkman]

Thanks! This were up last year, but I did not get any videos done because I ran the 2010 show. This year I have new sequences, so they will be in the video. From what I noticed they did not look too much different from when I strung them by hand.

[Jason Burge]

Great job! I need to do the same thing. Thanks for posting.