As for materials, I will list everything I used just as a guideline.... Though you are more than welcome to use the exact same items :D Materials: 40 High CFM 120mm fans -
I used 48v dual ball bearing Sunon fans that I was able to pick up on ebay for only around $3.25 a fan shipped LINK 40 Additional 120mm fans -
I used some that I was able to source locally for only $1.65 each that are around 30cfm at 12v Power Supply -
If you decide to go the 48v route like I did, try to find a surplus industrial powersupply for cheap on ebay. I found 40v 30A lambda power supply for only $37 that I picked up locally (It did weigh 180lbs though so I'm being generous with "picked up") and I used an old scrap computer power supply I had laying around for the 12v fans Power Cable Sheathing -
You only need to go this route if you want it to look professional, and decide to use multiple strands of smaller wire instead of large gauge power cables to the unit. I found some woven sheathing that gave it a great look at only around 65 cents a foot at the local aeronautical surplus store (though it is widely available online at places like partsexpress and etc). Power Cable Connector -
Again, this is only for multiple stranded cable, and if you decide for the cable not to be permanently attached. So I picked up a army surplus 13 pin connector on ebay and it was only around 6$ shipped. Wiring -
Always check the clearance racks at Lowes and Homedepot... I was able to pick up two 500ft spools of 14 gauge paired wires at only $11 dollars each (normally close to 80$ each)... and the amount of wire really depends on how far you want the power supply away from the unit Wire Nuts/ Electrical tape/Wire staples Lumbar -
You will need 2 sheets of half inch plywood, 4x 8ft 2x2's, 2x 8ft finished 1x2's, 2 1"x6"x8ft, and some random scraps Moulding -
2 Half round wood moulding 8ft long Fasteners -
Lots of Wood screws in various lengths (1-2.5"), #6 2" bolts with nuts and fender washers (~20 bolts/nuts and 40 washers), wood glue PVC Rain Gutter -
I chose an 8ft piece from Home Depot Pvc Drain Channel -
Im not sure exactly what its called, but its located with all the drains you bury at Lowes and comes in 5-6ft lengths, and you will need two of these, and a coupler... All of the holes on the top need to be widened with a drill bit, and 1ft needs to be cut off of only one of the pieces PVC Gutter Covers -
These are flap like pieces of pvc and are around 3-4ft long so you will need 2-3 of them. I purchased mine at Home Depot (they are 1ftx4ftx1mm roughly and have a huge sticker on one side of them).
Oh... and the single most important part.... Honeycomb -
A local aeronautical supplier provided me with some scraps luckily but you can always use plastic honeycomb (supermarketpartswarehouse) or even straws (the mythbusters approach) if you cant find the aluminum kind like I did.
A projector... Footage... and a fog machine (preferably that can do continuous fogging).... but these aren't part of this instructable...
Drill - With various bits
Jig Saw - you can honestly cut everything with this but a table saw works best for the long cuts (or a circular saw)
Hole Saw Bits - If you would like to use the power connectors
Soooo many zip ties...
Paint - I used the same Behr Ultra High Gloss Exterior Black that I used on my Hearse... expensive but it covers in one coat and is by far the best paint I've ever used on bare wood.
Handles - This makes moving it so much nicer
There are various small bolts and screws not included, but those will depend completely on your setup.
So... once you have all that in front of you... lets proceed :D
And Btw... the renders are from a c4d file I created for this instructable. If you want it to look at, let me know and I will send it to you :D that way you can print out the side template and just cut it out.