|
Name |
Watts |
Catalog No. |
Filament Shape |
G.E. Crystal Clear |
150 |
150A/CL |
vertical |
G.E Ceiling Fan Light |
60 |
60A15/CF CDC 2 |
C-shaped |
ABCO Chandelier Bulb |
60 |
60Bll/CD |
V-shaped |
Ace Tubular Bulb |
60 |
60T10 |
pentagonal |
Abco Clear |
75 |
75A19 Clear |
horizontal |
Ace Decorator Clr.Globe |
60 |
60G25 Clear |
C-shaped |
- utility knife or exacto knife
- metal straight edge
- clear strapping tape, 2" wide-this becomes a structural element; it makes the top hole stronger and protects the box surface around the windows from the repeated use of tape
- 6 clamp light cords: Eagle brand #484 suggested, but any clamp light will do if you remove the clamp and the reflector
- cutting surface to protect table (scrap of masonite or wood)
- (optional) duct tape for reinforcing the bottom edges
- (optional) band saw for cutting flaps off
Making the Square Light Source
- While the
box is still flat, cut flaps off one end with a band-saw, utility
knife or exacto knife. If using a knife, use the metal straight
edge to guide the cuts. Straight cuts will prevent light leaks.
The cut edges will become the bottom of the light box (Figure
1A).
- Make a template
to use when cutting the windows, a rectangle measuring 3-7/8" x
2" (Figure 2).
- Next, while
the box is still flat, you need to draw and then cut out the
windows. The location of the windows is critical. Keep
the following pointers in mind:
- All windows are the same size, 3-7/8" wide and 2" high.
- All windows are centered with respect to the sides of the box, but the windows in each box are of at a different height so as to insure that the images from the light bulb will appear on the table or screen.
Now, using the template, draw the windows on the box, using the following guidelines for each box (Figure 1B):
Size of Box
Distance between bottom of window and bottom of box (inches)
8-1/2" cube
1-1/2 9" cube
1-3/4 10" cube
2 10-1/2" cube
2-3/4 11" cube
3-1/4 12" cube
3-1/4 - Cut
out the windows.
- Make
a frame around each window
with 2" strapping tape. This
will protect the box from
tearing with repeated use
of tape to attach the paper
or foil masks (Figure 1C).
- With
the box
still flat,
cut four
1" square
holes in
the top
for ventilation
of the
box (Figure
1E).
- With
the
box
still
flat,
measure
the
center
of
the
two
flaps.
Make
an
arrow-shaped
cut,
with
the
point
of
the
arrow
at
the
center
mark
(Figure
1D).
- Fold
to
construct
the
box,
and
stand
it
on
the
table,
with
open
side
down
(Figure
3).
- Tape
seam
where
flaps
meet,
outside
and
inside
of
box,
then
add
a
short
piece
of
tape
across
the
arrow-shaped
cut.
This
will
become
the
hole
for
the
light
fixture
(Figure
3A).
- Make 4 cuts where the strapping tapes cross, forming an asterisk shape, to conform with the cuts in the box (Figure 3B).
When the box has been used several times, reinforce the area around the hole with short pieces of strapping tape, and re-make the cuts to reinforce the hole for the light fixture.
* Note: Making these in graduated sizes facilitates storage since boxes fit into each other, however they can be all of one size. The light sources made from boxes are lighter, more inexpensive, and easier to store, but the round light sources made from molds used for cement are more durable.
