Step 7: Diffusers and Plastic Inlays

Unfortunately, the flat-top LEDs aren't quite enough to diffuse the light, so additional diffusing is required.  I added two diffusers; a layer of ordinary printer paper, and frosting on the underside of the plastic.

To frost the glass, I used Rustoleum "Frosted Glass" spray paint.  This is entirely unnecessary; sanding the plastic will work just as well.  Whichever method you use, make sure you spray/sand the underside of the plastic.  That is, the side that will eventually be glued down.  The shiny side of the plastic should be visible.

To make the paper diffusers, I simply traced the outlines of the plastic pieces onto white paper, and cut them out slightly smaller than the plastic.

With the frosting and paper diffusers complete, everything can be mounted onto the star frame.  Glue the paper diffusers in first, by applying a thin layer of white glue to the ledge and then carefully placing the paper in place.  Glue in the plastic inlays next, by applying glue to the edge of the ledge only and carefully placing the plastic.  Use white glue or epoxy for this; it doesn't really matter which.  Just don't use too much - ideally, the glue should not be visible, and should not squeeze out.
All I want for Christmas now is a scroll saw, amazing job!
Thanks! The scroll saw is probably my favourite tool in my workshop. It's amazingly versatile, while also very precise.
Could you recommend a particular brand? Are they all the same size? Can you use a metal cutting blade?
Well, I'd definitely recommend the <a href="http://www.dewalt.com/tools/machinery-scroll-saws-dw788.aspx" rel="nofollow">DeWalt DW788</a>, which is the one I have.&nbsp; It's probably the best scroll saw you can get for under $1000.&nbsp; The size of a scroll saw can vary, from 15&quot; to 24&quot;.&nbsp; The DeWalt is 20&quot;, which is enough for me.&nbsp; What I like about this one is the speed control, it's relatively quiet, and it doesn't vibrate all over the place like my old Craftsman scroll saw.&nbsp; It can accept any plain-end blade, from thin puzzle and jeweler's blades, up to thick rough-cut blades.<br> <br> You can use a metal cutting blade!&nbsp; I've done so myself.&nbsp; I've used it to cut aluminum plate and brass tubing.&nbsp; The resulting edge almost always a little jagged though, so be prepared to sand the edges.&nbsp; Perhaps I was using lousy blades...<br>
I would also recommend the Dewalt DW788 - I just purchased one for $450, it came with the stand and light. Also I use Flying Dutchman Ultra Reverse Blades. To remove the paper pattern from the wood, I use a heat gun.
That's pretty much the deal I found, only in Canadian dollars. ;)
Wonderful information - thank you ever so much, I think this is just what I need, and have needed, but I didn't know what it could do. I use my jewelers saws for so much and it is slow going on a big piece of metal - like a street sign.
Wow! You cut up street signs to make stuff?? The better tool for that is a <a href="http://www.sears.com/shc/s/p_10153_12605_00921400000P?prdNo=4&blockNo=4&blockType=G4" rel="nofollow">small band saw</a> with a metal cutting blade, but it's not as precise. The band saw will cut faster through thicker metal than the scroll saw is able to.
I have a 15 inch bandsaw, pretty big, I love it but it can't do what this scroll saw seems to be able to do. I can use the band saw for the big stuff for sure. I have the Dewalt in my shopping cart on Amazon, I'm going to sleep on it before I hit the buynow button. Thank you so much for your help.
Well, if you've got the bandsaw already then I guess the next step is a scroll saw. I managed to find mine at a brick-and-mortar store for $400. I suggest shopping around before hitting that button. Also, if you have any more questions feel free to ask here or PM me!<br> <br> Oh! As for blades, I usually get mine <a href="http://www.mikesworkshop.com/blades.htm" rel="nofollow">here</a>.&nbsp; Super-nice guy, great prices, lots of selection.<br>
please make one with shaun cassidy;s name. i'll buy it.
I see you're quite the fan...
This is the awesomesauce. Next gift exchange, my name is spelled s-c-o-o-c-h-m-a-r-o-o :D
You know, a nameplate was actually on my list of possible things to make!
This turned out fantastic - Teaghan is a lucky kid!
She certainly is, in more ways than a simple nameplate! Also, thanks. :)

About This Instructable




Bio: By day, Jeff is the Jack of All Robots at Clearpath Robotics. By night, a mad scientist / hacker / artist / industrial designer wannabe!
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