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BillAd
10-27-2007, 02:27 PM
Here are a few pictures of the enclosure that I am using to contain my 16 channel XMUS boards. The first shows a completed tube on a simple stand made from 1/4 inch threaded rod. The remaining pictures attempt to show the basic construction approach.

Cost is low and construction is quite simple. The following are the parts and dimensions that I used:

- 8 1/2 inch piece of 4 inch plastic drain pipe
- 4 inch plastic end cap
- 1 wood disk made from 1 1/2 inch pine (two pieces of 3/4 inch pine glued together) cut to fit inside the pvc pipe. (I turned mine on a lathe to make a slight lip on the bottom. However a jig saw should also work well enough)
- 1/2 inch piece of plywood 3 1/4 by 7 3/4
- 1/2 of a piece of grounding bar to secure the ground wires
- Small block of wood to clamp down the cords
- A few nuts and bolts
- Black paint

(note the last picture shows a wired board. In this picture only 8 of the 16 channels are wired although the slots are drilled for the remaining 8 wires and there is plenty of room for all to fit)

BillAd
10-27-2007, 02:28 PM
And one last picture looking down from the top:

xmus
10-27-2007, 03:34 PM
VERY NICE! The first picture makes the tube look HUGE (like the size of an office garbage can) but in the rest, I can see what a great design that is!

Mudsculpter
10-27-2007, 04:30 PM
A thing of beauty,.... I have similar enclosures for my SSRs but I love your solution to the base and stand. Now its off to dig up my router and circle cutter kit.

JohnByrne
10-27-2007, 06:27 PM
Ohhhhhhhh I'm going to do this! Thank you!

wjohn
10-27-2007, 06:55 PM
That,

Sir,

I truely a thing of wonder.

xmus
10-27-2007, 06:58 PM
I've already purchased material to build 3 of these....
(not using wood for the cork, just another cap!)

Wayne J
10-27-2007, 09:08 PM
WOW.... Bill, you make some REALLY COOL stuff! Glad to have you onboard! :)

Mudsculpter
10-27-2007, 10:44 PM
Looks like you have some walnut scraps in there,.......fancy

xmus
10-28-2007, 03:00 AM
Bill you are ingenious, these are quite fast to build. And the cost is about 1/3 of a watermaster (I'm guessing about $10 each).

I love the watermasters, but i have 3 trees, that aren't very big, that i need to put these behind, and the watermasters do NOT hide behind the trees at all, it looked really awkward... These are going to solve that.

So I'm going actually screw these to a tree with some strapping, I'll rivet the strapping to the tube, and then just screw through...

To "lock" these, I'll use a 1/2" sheet metal screw through the caps.
The source of power has a GFI, so I'll survive without a GFI in the case.
And come to think of it, the outlets in my office are GFI'ed... so I think I'm safe even though these don't have a GFI.

klanger
10-28-2007, 10:56 AM
I'll bet the neighbours will be worried when they see them with wires hanging out of them under the tree.

Kev

Macrosill
10-28-2007, 11:05 AM
I'll bet the neighbours will be worried when they see them with wires hanging out of them under the tree.

Kev
LOL, good point!

xmus
10-28-2007, 11:40 AM
Are you implying they might look like a very very large M80? grin. The fuse on a "cherry bomb" is green! And I'm using green wire! Perfect!

Wayne J
10-28-2007, 12:13 PM
Are you implying they might look like a very very large M80? grin. The fuse on a "cherry bomb" is green! And I'm using green wire! Perfect!


http://i4.photobucket.com/albums/y122/MERC460/smileys/kieran-tnt.gif

XmasInGalt
10-28-2007, 12:45 PM
Bill, Great job!!!! That's exactly what I was looking for to enclose my Renards. I've been working on a enclosure for the 4 port SSR. Here is one I'm working on. As soon as I'm done making 20 of these, I'm going to use your design to make the enclosures for my Renards. Thanks!!!!!!

XmasInGalt
10-28-2007, 12:47 PM
Sorry. I forgot to reduce the size of the pics before attaching them to the post.

xmus
10-28-2007, 01:09 PM
XmasInGalt, how did you make that bottom plate with the receptacle holes, and the RJ45 jack hole?

This solves the problem of having the plug-ins in the puddles and collecting rain.... great idea to point them down, and have them under the tube..

also, if you want to make the picture smaller, go back and click edit, and change the picture if you like.

Dave

XmasInGalt
10-28-2007, 02:38 PM
Dave,

I used a scrollsaw on the low speed setting then used a hand file to fit the RJ45 into the hole. It took about 15 minutes per plate to cut and file. These plates are very brittle so it doesn't take alot to crack them. I had to glue a few cause I got a little anxious to get them done.

xmus
10-28-2007, 03:39 PM
Dave,

I used a scrollsaw on the low speed setting then used a hand file to fit the RJ45 into the hole. It took about 15 minutes per plate to cut and file. These plates are very brittle so it doesn't take alot to crack them. I had to glue a few cause I got a little anxious to get them done.

So they are just thin wood (plywood?)

DavidHenry
10-28-2007, 07:48 PM
Are the bus connectors (used for the neutral wire) custom made, or are they available somewhere? After my first indoor no box test setup with 2 SSR boards, I realized that I need to find a good way to string all the neutral wires together.

David

BillAd
10-28-2007, 08:13 PM
David,

THe bus connector is a circuit breaker box ground bar. These can be purchased in the electrical department at Lowes, HomeDepot, etc. Price is in the $6.00 range and in my enclosure I cut my in 1/2 and placed two wires under each screw terminal. For example:

http://www.lowes.com/lowes/lkn?action=productDetail&productId=94117-82364-GBK21CS&lpage=none

Bill

XmasInGalt
10-28-2007, 08:23 PM
So they are just thin wood (plywood?)[/quote]

Dave,

They are regular wall plates. I just cut the shape to match the 4" pipe connector.

xmus
10-28-2007, 08:36 PM
"They are regular wall plates."

I see why they are so fragile now! I don't own any Sean Bowf style SSR's, but maybe you could do the same thing with metal face places?

XmasInGalt
10-28-2007, 09:05 PM
I was considering metal face plates or thicker plexiglass. I think I'l get a metal blade for the scrollsaw and give one a shot.

xmus
10-30-2007, 12:39 AM
Bill,

I'm dreaming of a mega tree xmus tube, with 32 channels :) Should be easy enough eh?

BillAd
10-30-2007, 08:50 AM
Dave,

A mega tree rocket? Can't wait to see the pics!

Bill

xmus
10-30-2007, 09:43 AM
Dave,

A mega tree rocket? Can't wait to see the pics!

Bill

Well I wont build it until after Halloween, I need to pull some enclosures down, and harvest some controllers. I can't believe I might actually use all 12 controllers this year. Crazy.

fcky529
11-04-2007, 04:46 AM
very nice, clean design/assembly xmasingalt, if it weren't for the seam between the cap and coupler, it could pass for a production item

xmus
11-04-2007, 04:58 AM
Dave,

A mega tree rocket? Can't wait to see the pics!

Bill

http://www.doityourselfchristmas.com/forum/viewtopic.php?t=1040&highlight=bazooka
I'm actually calling it the Bazooka :)

xmus
11-05-2007, 11:12 AM
All my controllers are deployed.
2 serial ports, 5 controllers each.

1 indoors
3 orbit water masters outdoors
3 xmus tubes
3 controllers in one bazooka

Last night I upgraded to Vixen 2.0.3.3 Beta3, and it is working fine.
I ran a test sequence (put one candy cane on every controller) and things are alive and well.

:)

Now I just need to get 30 candy canes, 6 strings of chaser lights, and "snowflakes" deployed! (And the only think I have left to purchase is 1400' of SPT1). Getting there.... getting there....

bonuts
11-30-2007, 12:51 AM
What is the black stuff inside the pipe? Some kind of spray?

http://www.doityourselfchristmas.com/forum/files/web_img_0070_168.jpg

xmus
11-30-2007, 02:10 AM
That is just the natural color of the inside of that type of PVC pipe. I hadn't painted it yet in that picture. Go back a few posts in this thread, I painted them black eventually on the outside.

XmasInGalt
01-20-2008, 11:56 PM
Here are a couple of pics of the 4 SSR tube that I used in my display this year.

Slush
01-21-2008, 11:36 PM
Here is a picture of mine. It cost $5.20 and included a gallon of ice cream.:)

Notice high wind device (2.5 lb weight) used to anchor this high tech device.

Dan Ross
01-21-2008, 11:55 PM
It cost $5.20 and included a gallon of ice cream.:)

I bet I could get my wife to help me assemble these. :)

tconley
01-22-2008, 12:11 AM
I made similar pill box style housing for my ssr but to mount them i went the easy way. pounded 2 18" peices of rebard about 8 inches in the ground. Then simply use 2 large house clamps and a nut driver to lock it all into place. I worked like a cham. From there the 9 ft extension for each channel fanned out.

WWNF911
01-22-2008, 04:01 AM
Bill, Great job!!!! That's exactly what I was looking for to enclose my Renards. I've been working on a enclosure for the 4 port SSR. Here is one I'm working on. As soon as I'm done making 20 of these, I'm going to use your design to make the enclosures for my Renards. Thanks!!!!!!

Terrific design! What was the cost per unit?

XmasInGalt
01-22-2008, 10:28 PM
The cost per unit was a little over $4.00 each. I found that there was a big difference between Lowes and Home Depot on the same items. I purchased all the parts from Home Depot because their price was lower overall and they had the Nylon wall plates that are easier to cut than the standard wall plates.

JEEPGUY
01-24-2008, 03:43 AM
I am making mine like XmasInGalt's except I glued and screwed a piece of 1/2" Sch 40 for the stake. I'm going to use a piece of rebar to stick into the ground and slip the sch 40 stake over it.


http://www.lewisholidaylights.net-a.googlepages.com/SSREnclosures.JPG/SSREnclosures-full;init:.JPG

WWNF911
01-24-2008, 04:01 AM
Will be interested to see your finished design.

biffklg
01-24-2008, 09:22 AM
What kind of paint do you guys use to paint these tubes? I tried regular spray paint and some of the expensive "just for plastic" spray paint. It didn't see to matter which kind, if you touched it wrong the paint scratched off easily.

JEEPGUY
01-24-2008, 10:22 PM
I used Rustoleum glossy one the one that I painted. I did a scratch test and it seems that it scrapes off easily on the 1/2 " sch 40, but harder to do so on the 4" PVC

Trepidati0n
01-24-2008, 10:29 PM
1. Run all your pieces through the dishwasher when you bring them home. There is a usually a very thing layer of crud from the process on their that makes pain not stick easily.

2. Lightly go over them with 100 grit sandpaper.

When I've done that before with painting PVC...it sticks a bit better.

WWNF911
01-25-2008, 04:39 AM
1. Run all your pieces through the dishwasher when you bring them home. There is a usually a very thing layer of crud from the process on their that makes pain not stick easily.

2. Lightly go over them with 100 grit sandpaper.

When I've done that before with painting PVC...it sticks a bit better.

I agree. No matter what you're painting, if it has a smooth surface it will fail the scratch test. Rough it up a bit to give the paint something to adhere to and you're in business.

dhavard
10-15-2008, 11:48 AM
I want to make a couple of these...if i don't use the wood piece on the bottom and i use another cap, what would be the best way to attach the board to keep it from moving around?

WWNF911
10-15-2008, 12:11 PM
I want to make a couple of these...if i don't use the wood piece on the bottom and i use another cap, what would be the best way to attach the board to keep it from moving around?

Just make the board a tight fit. Not too tight though :)

rstehle
10-15-2008, 12:12 PM
When I made mine, I used a couple of small metal angle brackets to attach the wood to the cap. You could also probably just screw thru the cap into the wood if the wood is not too thin.

WWNF911
10-15-2008, 12:13 PM
What kind of paint do you guys use to paint these tubes? I tried regular spray paint and some of the expensive "just for plastic" spray paint. It didn't see to matter which kind, if you touched it wrong the paint scratched off easily.

I've found some paint recently at Wal-mart Krylon I think that brags that its made for plastics, no sanding or priming needed. It's about $5 a can. We'll see if I get the same results.

dhavard
10-15-2008, 12:13 PM
lol guess my mind was in the gutter...lol I was not sticking to the K.I.S.S method that I always forget about. It seems like I have to make things more complicated than they are...lol Thanks!!

kenoman742
01-24-2013, 11:13 PM
I know this is an older thread but I was just wondering, is there any issue with heat build up inside the sealed tube?

Skunberg
01-25-2013, 03:03 AM
Welcome to DIYC. I don't think heat is a issue here in the states for Christmas stuff. Not in this application anyway. The guy's down under that's another story.

Brian

MarkL
01-25-2013, 12:09 PM
No issues for me. I've had three of these in PVC tubes running my megatree for several years. Each channel drives two 100 light incandescent strings, so 2/3 amp. My tree is 3 colors, and I interleave colors (i.e. channel 1 = Red, channel 2 = green, channel 3 = white, etc.) so all the channels of a controller will never be on at the same time. If you were to run the thing at full capacity continuously the store might be different.

I'm in central Texas by the way, so the ambient temperature isn't always cool.

Mark

Aurbo99
01-25-2013, 05:21 PM
I've used a very similar design for the last 5 years, completely sealed and water tight, never had an issue with heat build up

kenoman742
01-26-2013, 03:21 AM
Thank you very much for the quick response guys. I appreciate the help.

BillAd
01-26-2013, 09:36 PM
Hi,

I've had 10 running for 5 years with no issues. If you will be switching a heavy load then I believe the focus should be the heat sink rather than the enclosure.

Bill

kenoman742
01-27-2013, 05:18 AM
Thanks Bill. I'm going to try to use 100% LED's so load won't be an issue. I sure like the enclosure design and will probably make and use a couple this year.