Some things you just have to do yourself.
Layout of a star is important to the final look of the project so use a fully drawn mockup or jig to make it. Our 4 channel star needed 6 half-star pieces and was sized accordingly to the length of the lights that were put on it. In this project, the total length of 15 feet or 3 strands of garland lights for each star perimeter. Ten pieces of 1/2 inch PVC pipe were used and cut identical for each star section.
Two different cuts were needed on each piece of PVC pipe. The first cut was half of a 108 degree angle or 54 degrees. PVC glue was applied for temporary strength during construction, but drilling holes at the edges so that zipties were able to run through was just the strength we needed to secure the two pieces of PVC together.
The second cut is half of a 36 degree angle or 18 degrees. Most saws won't cut that angle so we clamped a block to the saw and angled it to 18 degrees from 90 degrees to make the cut. Keep the cut parallel to the other cut and opposite. Not shown are the holes drilled as above and 90 degrees from those for zipties to be added later. This joint was also glued for temporary strength.
The top of the star. Each piece was drilled with holes across for a ziptie to band them all together. Then 2 screws were put into a core piece equidistant apart for all 6 half-star pieces. Then glue was applied afterward for more strength.
The bottom of the star. Each half-star piece was attached the same way as above on a coupler with the screws in the center of the coupler. Ziptied and glued for strength. A small section of pipe was used as a riser with a Tee cut down and a strobe light screwed to it. Additional wire was added and fed through the pipe and coupler.
Assembled and put on its riser, it should look like this. The riser has a small slot cut at the top for the wires to be fed down through it to the bottom where the SSR will be. At the bottom of the riser are 2 3/8" holes so that it can be lagged into its roof support platform. Guy wires leading out from the star to the edges of the roof will also be needed to keep it vertical against the wind.
After being glued and ziptied together, paint it black. That way it won't reflect the white color of the pipe. Then ziptie the light strings on, starting at the bottom and going around the outside perimeter of each star piece. Be careful while handling as it will be a bit wobbly but it will hold together.
Here is the star with all four channels on. What a sight! Our neighbors think we are crazy making a star in July. Total number of lights used: 2101 (including the strobe.)
Sponsor Sign
Meanwhile.. Back at the branch.
GFI Branch Stake Project
