Build Plans: DIY Florescent Light Kit

POSTED BY Erik Beck, 14 April 2008

Hey everyone and welcome to the build plans for BFX episode #49, "DIY Light Kit". Keep in mind these are the plans for only one light and stand. You'll probably want to build two or more.

Shopping List:

• 1 Dual 4' florescent light fixture.
  (Get one that has the plug built in if you can. I'd also go with a T12 fixture.)
• 6' telescoping painters pole.
  (You could use an old broom pole instead.)
• One 3/4 in. "T" joint and cap.
  (We used steel, but you could probably get away with PVC.)
• Spray Paint.
  (silver or white.)
• Duct Tape.
  (Or gaffers tape, but duct tape is cheaper.)
• Two 4' bulbs of your choice.
  (Buy "soft white" to replicate indoor light and "sunlight" for outside light.)
• Zip Ties.
  (Make sure they're long enough)
• 2 Wooden dowls or paint stir sticks.
  (This is to add rigidity to the cardboard, just like in the Sandwich Costume.)
• 40 lb bag of concrete.
  (Pre-mixed and ready to go)
• A 2 gallon plastic bucket.
  (With a handle!)
• 10" length of PVC pipe with a 1" outer diameter.
  (Just make sure your painters pole will slide into this piece.)

The Base

This is pretty easy. Mix up your concrete according to the directions on the bag. We had a big mixer attachment that hooked to our drill that helped the process a lot. Once your concrete is ready pour it into the bucket. Take your PVC, cap one end and sink it into the center of the concrete. This will be your achor that the painter pole will slide into. To make sure it's straight slide the pole in and use a level to adjust the PVC while the concrete is still wet. As this dries we can move on to the fixture.

The Light Fixture

Depending on the light fixture you get, some assemble may be required. We had to wire in our own plug. All I did was cut off the end of an extenstion cord and wire it in with some wire nuts. To make sure the wire doesn't pull out of the fixture tie a knot into the wire before it exits the fixture.

The Barn Doors

Make sure and save the box the light fixture came in. You should be able to cut the larger panels from the box. They will be the perfect width and length for custom barn doors. Tape your wooden dowels or paint stir sticks to the outside of each cardboard panel, then cover the rest of the surface in tape. To attach them to the light simply tape them in place. Don't worry about the cardboard and tape getting hot. Florescent lights don't get hot! To keep your barn doors in the position you want simple tape some 10 or 12 gauge wire to the ends. Finish up by spray painting the inside of the doors and fixture silver.

The Mount

Drill 4 holes in the back of your fixture. Drill the holes near the center of the fixture, but closer to the ballast (that heavy black box inside the light). Now you can use zip ties to secure your "T" joint in place. Don't forget to cap off the top of the "T" so that your painters pole doesn't slide right through.

Conclusion

This is a very simple, flexible and useful rig. You should built two! Make sure and watch the episode that goes with these plans and leave any questions in the comments below.

THANKS!