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http://indianaquariumhobbyist.com/community/ :: View topic - Sun-board lighting unit DIY - Dimensions on page 2
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Sun-board lighting unit DIY - Dimensions on page 2
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Nidhi
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PostPosted: Mon Apr 14, 2014 10:47 am Post subject: Sun-board lighting unit DIY - Dimensions on page 2 Reply with quote

 Hi  all,  
 My  earlier  "DIY  55W  X  2  PLL  Lighting  fixture"  worked  pretty  well,  but  didn't  give  enough  spread  as  it  was  kept  pretty  close  to  the  water  surface..  although,  the  plan  was  to  suspend  it  at  least  12  inches  from  the  surface.  I  was  unable  to  find  suitable  materials  to  make  the  hanging  arrangement,  so  I  just  sold  off  the  lighting  unit..  Very Happy  
   http://indianaquariumhobbyist.com/community/modules.php?name=Forums&file=viewtopic&t=35894..
 
 Later,  bought  a  used  3  footer  Chinese  lighting  unit  from  a  fellow  IAHian  which  had  21w  x  2  T5  bulbs  with  the  pure  intention  of  replacing  the  T5  with  36w  x  2  bulbs..  But,  couldn't   do  it  due  to  many  factors  which  cant  be  discussed  here.  So  had  to  sell  it  off  too..   Smile  
 
 After  this  ordeal,  decided  to  go  for  a  complete  DIY  unit  using  Sunboard  (Foamboard)..
 The  plan  was  to  use  a  combination  of  T5  and  PLL  to  get  around  100-110W  of  lighting  which  would  give  even  spread  of  light  over  the  3  footer  tank..
 So,  the  list  of  parts  are..
 1.  Osram  36W  PLL  tube..  2  nos.
 2.  Osram  ballast  for  the  PLL  bulbs..  2nos.
 3.  Chinese  make  21W  T5  tubes  which  are  34  inches  long..  2nos.
 4.  Phillips  chokes  for  the  21W  tubes..  2nos.
 5.  Holders  for  the  T5  and  PLL..  4  and  2nos  respectively.
 6.  Toggle  switches,  SPST  (ON/Off)..  2  nos.
 7.  Moulded  2  pin  plug  with  1.5  meter  wire..  1no.
 8.  Sunboard  4x2  feet  piece..  1no.
 9.  locktite  instant  adhesive..  1  bottle.
 10.  Wires,  Screws  and  nuts..  as  required.
 
 Tools  required..
 knife,  metallic  ruler  or  channels,  measuring  tape,  poker  (  sharp  tool  to  make  holes),  screw  driver,  insulation  tape,  etc..
 
 The  Sunboard  is  marked  and  cut  as  per  required  dimension..
 
 
 The  above  pieces  were  later  re-done  with  the  bottom  part  extended  up  to  4  inches  to  become  part  of  the  mounting  legs  of  the  unit.
 
 
 You  will  need  hell  lot  of  patience  to  cut  these  Sunboards..  
 
 This  is  the  main  board  which  acts  like  a  chassis  for  the  lighting  unit,  so  it  needed  a  bit  of  reinforcement  to  prevent  it  from  sagging..
 
 
 Just  mounted  the  PLL  holder  with  screws  so  that  the  side  board  could  be  held  in  place..
 
 
 Then  mounted  the  T5  bulb  holder  and  inserted  all  the  bulbs,  just  to  make  sure  all  is  well  before  glueing  them  together..
 
 
 Lets  take  break  for  now..


Last edited by Nidhi on Tue Apr 15, 2014 3:30 pm; edited 1 time in total
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josyjames
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PostPosted: Mon Apr 14, 2014 11:21 am Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Very  good  project  Nidhi..
 
 Do  you  have  any  plan  to  use  reflectors?  Also  do  you  have  any  plan  to  paint  the  sun-board  or  just  use  it  as  it  is?
 
 Would  look  good  if  you  spray  paint  the  top  of  the  sun-board.  And  where  are  you  keeping  the  ballast?
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Nidhi
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PostPosted: Mon Apr 14, 2014 11:27 am Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Now,  since  everything  looked  OK..  went  ahead  and  glued  all  the  Sunboard  parts  together  as  per  plan..
 The  new  side  board  with  the  extended  bottom  can  be  seen  here..
 
 
 A  view  from  above,  I  wanted  to  conceal  the  wiring  and  the  chokes  in  a  separate  compartment  on  top..  
 
 
 Here  is  the  view  after  mounting  of  the  chokes  and  wiring  is  completed..
 
 
 Test  driving  it  for  the  first  time..  I  have  used  two  toggle  switches,  one  to  switch  on  the  PLL  and  another  for  T5..
 
 
 Completed  the  mounting  legs  part  and  tested  it  on  the  tank..  you  can  see  that  the  choke  compartment  is  concealed  with  another  Sunboard  piece  screwed  in  for  easy  maintenance.  2  toggle  switches  are  also  mounted  on  the  same  piece.
 
 
 Front  view..
 
 
 The  lighting  has  good  spread  now  ,  but  looks  like  I  over  did  the  height  part  since  lots  of  light  is  hitting  outside  the  tank,  will  be  trying  to  reduce  the  height  some  how..
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Nidhi
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PostPosted: Mon Apr 14, 2014 11:40 am Post subject: Re: Sun-board lighting unit DIY Reply with quote

                                                   
josyjames  wrote  (View  Post):                
Very  good  project  Nidhi..
 
 Do  you  have  any  plan  to  use  reflectors?  Also  do  you  have  any  plan  to  paint  the  sun-board  or  just  use  it  as  it  is?
 
 Would  look  good  if  you  spray  paint  the  top  of  the  sun-board.  And  where  are  you  keeping  the  ballast?                

 Thanks  Shelly,  I  am  trying  to  source  the  reflectors..  Do  you  know  any  place  to  buy  them.
 Right  now  not  decided  on  the  painting  part..  may  be,  will  give  it  a  go  later  on..   Thumb Up  
 I  have  shown  the  chokes  mounting  part  in  the  next  post..  check  it  out.
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saikumar
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PostPosted: Mon Apr 14, 2014 4:01 pm Post subject: Re: Sun-board lighting unit DIY Reply with quote

 looks  superb  boss!  Thumb Up  I  agree  on  the  height  too,  quite  a  lot  of  spill.  But  as  your  main  aim  was  12"  suspension,  I  think  you  can  put  a  front  and  rear  glare  sheet,  so  spill  will  be  reduced.
 
 But  all  together  great  craftmanship,  can  you  also  provide  us  all  with  dimensions  of  cuts,  angles,  thickness  etc?
 
 
 BTW  is  the  plan  to  add  some  food  packets  in  that  corner  pockets?   Very Happy
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Nidhi
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PostPosted: Mon Apr 14, 2014 4:56 pm Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Thanks  Sai..
 The  thickness  of  the  foamboard  is  5mm,  will  make  a  drawing  for  the  cutting  dimension  and  post  as  soon  as  possible..
 He..  he,  no  pockets  in  there,  just  mechanical  support  for  the  legs..  Chuckle
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abhip29
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PostPosted: Mon Apr 14, 2014 8:01 pm Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Nice  Design..  Btw,  wouldn't  sunboard  succumb  to  heat?
 
 Regards,
 ABHILASH
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Nidhi
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PostPosted: Mon Apr 14, 2014 8:28 pm Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Abhilash..  I  have  seen  many  people  using  the  foam  board  as  top  cover  with  almost  same  wattage  of  lighting..  my  guess  is  that  the  PLL  bulbs  might  warm  up  a  bit.  The  T5  just  barely  warm  up..
 Thanks  for  pointing  it  out  though..  will  monitor  the  effects  of  heat  very  closely.
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vram
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PostPosted: Mon Apr 14, 2014 8:38 pm Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Very  nice-looking  unit!   I  made  a  6  feet  hood  out  of  sun  board  (i  had  to  stick  two  layers  of  5mm  to  prevent  bending  although  I  should  have  probably  gone  with  the  10mm  thickness)  and  it  is  really  easy  to  work  with  compared  to  wood.   I  hadn't  made  any  provision  for  ventilation  though  and  was  worried  about  it  getting  overheated  but  never  got  a  chance  to  test  it  as  I  then  got  a  wooden  canopy  made  for  other  reasons.   I  am  interested  to  know  how  your  setup  fares  though.
 
 thanks
 shankar
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Scorpio
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PostPosted: Mon Apr 14, 2014 8:42 pm Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Very  Nice  and  neat  project.
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Preeths
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PostPosted: Mon Apr 14, 2014 10:22 pm Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Hi  Nidhi,
 
 This  is  a  nice  DIY,   the  problem  i  face  with  most  of  my  tank  tops  is  that  after  a  few  months,  the  inside  reflective  gets  black  due  to  Fungus,  do  you  have  any  idea  how  to  prevent  that  from  happening?  Too  much  heat  will  make  the  adhesive  brittle  and  the  joints  might  come  loose,  have  you  found  a  solution  for  that?
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Nidhi
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PostPosted: Tue Apr 15, 2014 8:46 am Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Thanks  Shankar,  I  think  5  mm  will  cope  with  the  heat  pretty  well..  but  6  foot  canopy  is  a  different  story..  Chuckle  
 
 Thanks  Scorpio..  Smile  
 
 Thanks  Preetham,  A  well  ventilated  hood  don't  have  issues  with  fungus,  dampness  or  moisture  accumulation  is  the  main  cause  of  fungus.  I  think  water  vapour  from  my  tank  will  get  diffused  out  side  the  hood  and  very  little  will  get  inside  it  to  promote  fungus.  I  am  still  not  sure  how  much  heat  is  being  generated.  And  yes,  you  are  right  about  the  adhesive  becoming  brittle  and  the  joints  coming  loose.  I  had  this  issue  while  using  3mm  foamboards.  That's  the  reason  for  going  into  a  thicker  gauge  this  time  around.
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garothmaan
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PostPosted: Tue Apr 15, 2014 11:45 am Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Clapping   Clapping   Clapping   very  impressive.  I  am  using  your  project  for  my  3ft  planted  tank.  What  adhesive  you  have  used  for  sticking?
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Nidhi
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PostPosted: Tue Apr 15, 2014 11:59 am Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Thanks  Garothmaan,  
 You  are  welcome  to  try  it..  I  will  update  with  a  cutting  dimensions  which  will  be  useful  for  you...  
 I  used  a  adhesive  from  locktite.  You  can  use  fewikwik  instead..
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Thuds
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PostPosted: Tue Apr 15, 2014 1:53 pm Post subject: Re: Sun-board lighting unit DIY Reply with quote

 Very  interesting  new  project  hope  it  does  not  buckle  with  heat  keep  us  posted.
 
 Thuds
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