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Nidhi
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Joined: Nov 23, 2011
Posts: 1881
Location: Bangalore, Prakashnagar.
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 Posted: Mon Apr 14, 2014 10:47 am Post subject: Sun-board lighting unit DIY - Dimensions on page 2 |
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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.. 
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.. 
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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Joined: Apr 21, 2010
Posts: 2500
Location: Bangalore-Ramamurthy Nagar
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| Posted: Mon Apr 14, 2014 11:21 am Post subject: Re: Sun-board lighting unit DIY |
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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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Joined: Nov 23, 2011
Posts: 1881
Location: Bangalore, Prakashnagar.
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| Posted: Mon Apr 14, 2014 11:27 am Post subject: Re: Sun-board lighting unit DIY |
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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
Committed Member of IAH
Joined: Nov 23, 2011
Posts: 1881
Location: Bangalore, Prakashnagar.
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| Posted: Mon Apr 14, 2014 11:40 am Post subject: Re: Sun-board lighting unit DIY |
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| josyjames wrote (View Post):
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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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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.. 
I have shown the chokes mounting part in the next post.. check it out. |
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saikumar
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Joined: Jan 30, 2007
Posts: 2226
Location: HYD-is-good
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| Posted: Mon Apr 14, 2014 4:01 pm Post subject: Re: Sun-board lighting unit DIY |
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looks superb boss! 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? |
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Nidhi
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Posts: 1881
Location: Bangalore, Prakashnagar.
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| Posted: Mon Apr 14, 2014 4:56 pm Post subject: Re: Sun-board lighting unit DIY |
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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..  |
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abhip29
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Joined: Sep 10, 2012
Posts: 149
Location: Mysore
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| Posted: Mon Apr 14, 2014 8:01 pm Post subject: Re: Sun-board lighting unit DIY |
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Nice Design.. Btw, wouldn't sunboard succumb to heat?
Regards,
ABHILASH |
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Nidhi
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Joined: Nov 23, 2011
Posts: 1881
Location: Bangalore, Prakashnagar.
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| Posted: Mon Apr 14, 2014 8:28 pm Post subject: Re: Sun-board lighting unit DIY |
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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
IAH New Member
Joined: Sep 27, 2008
Posts: 54
Location: Bangalore
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| Posted: Mon Apr 14, 2014 8:38 pm Post subject: Re: Sun-board lighting unit DIY |
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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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Joined: Dec 07, 2007
Posts: 2381
Location: Delhi
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| Posted: Mon Apr 14, 2014 8:42 pm Post subject: Re: Sun-board lighting unit DIY |
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| Very Nice and neat project. |
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Preeths
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Joined: Nov 07, 2007
Posts: 2041
Location: Bangalore
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| Posted: Mon Apr 14, 2014 10:22 pm Post subject: Re: Sun-board lighting unit DIY |
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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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Posts: 1881
Location: Bangalore, Prakashnagar.
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| Posted: Tue Apr 15, 2014 8:46 am Post subject: Re: Sun-board lighting unit DIY |
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Thanks Shankar, I think 5 mm will cope with the heat pretty well.. but 6 foot canopy is a different story..
Thanks Scorpio..
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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Joined: Jun 11, 2008
Posts: 3506
Location: Mumbai, Bharat (AKA...INDIA)
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| Posted: Tue Apr 15, 2014 11:45 am Post subject: Re: Sun-board lighting unit DIY |
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 very impressive. I am using your project for my 3ft planted tank. What adhesive you have used for sticking? |
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Nidhi
Committed Member of IAH
Joined: Nov 23, 2011
Posts: 1881
Location: Bangalore, Prakashnagar.
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| Posted: Tue Apr 15, 2014 11:59 am Post subject: Re: Sun-board lighting unit DIY |
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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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Joined: Jun 28, 2011
Posts: 659
Location: Mumbai
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| Posted: Tue Apr 15, 2014 1:53 pm Post subject: Re: Sun-board lighting unit DIY |
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Very interesting new project hope it does not buckle with heat keep us posted.
Thuds |
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