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| Part | Quantity | Price | Total |
|---|---|---|---|
| 8 ft. Corrugated Galvanized Steel Utility-Gauge Roof Panel | 1 | $14.36 | $14.36 |
| 4 ft. x 4 ft. Sanded Plywood | 1 | $23.00 | $23.00 |
| GE Lighting 74456 GE332MAX-G-N 120/277-Volt Multi-Volt ProLine Electronic Fluorescent T8 Instant Start Ballast 3 or 2 F32T8 Lamps | 1 | $14.52 | $14.52 |
| Non-shunted Turn Type T8 Lamp Holder JACKYLED 12-Pack (Only need 3) | 1 | $9.99 | $9.99 |
| Osram UVC T8 Tubes - G30T8/OF | 3 | $10.69 | $32.07 |
Build Process Steps
Procure materials from Home Improvement store or similar that you have in stock.
Measure 48 inches (or half the panel) and mark.
Using an angle grinder with a metal cutting disc, cut the corrugated metal sheet in half.
Calculate the radius of the circle that the corrugate metal will form and mark the center and diameter on the plywood. (For the metal panel in the BoM the circle is 16.5” inches in diameter, 8.25” in radius)
Have some help in holding the corrugated panel to form the half cylinder and mark the inside profile on the plywood.
Using a jigsaw cut the profile four times. Tip. Cut the top of the profile first and then the individual groves.
Hold the end caps together and sand them to be even.
From the plywood, or any available wood profile cut the four 48” long edges and mark and cut the endcaps.
Use glue and wood screws to attach the edges to the endcaps.
Use glue and wood screws to attach the edges to the endcaps.
Apply the weathering strip to the inside edge of the corrugated panel. (this will seal the gaps between the profile of the endcaps and the corrugated metal panel)
Lay the metal corrugated panel over the assembled end caps with the edges.
Using wood screws and/ or nails attach the corrugated panel to the endcaps and edges.
Using wood screws and/ or nails attach the corrugated panel to the endcaps and edges.
Build two of the half cylinders sections.
Build two of the half cylinders sections.
Attach the two halves with the piano hinge.
Attach the two halves with the piano hinge.
Cut a slanted leg to prevent the unit to fall over when the top half is opened, and attach the legs to the bottom half of the unit.
Attach a string between the two halves to prevent the top half to fall over back.
Attach the T8 fluorescent lamp holder to the corrugated metal, spacing them on the cylinder at approximate 120 degrees. Place two lamps on the bottom half and one lamp on the top half. Use the corrugations to approximate the spacing. With this corrugated panel the linear segment is approximative 10 degrees (18 segments for the entire half), so count 12 segments in between the lights.
Secure the lamp holders with a rivet in the back to prevent it for sliding back.
Secure the lamp holders with a rivet in the back to prevent it for sliding back.
Wire the lamp holders according to the diagram on the start ballast. Protect the wire entry holes through the corrugated metal with gromets, or electrical tape.
Wire the lamp holders according to the diagram on the start ballast. Protect the wire entry holes through the corrugated metal with gromets, or electrical tape.
Cover the exposed internal wire with aluminum tape to prevent plastic deterioration due to UV exposure.
Attach the power switch in line with the start ballast and connect the power cord.
Warning: Do not power the unit without eye protection. Use laser protection glasses.