This instructable is our effort to win the most awesome grand prize for the Shopbot contest. I am part of a very small group of friends, artists and creative engineers who are constantly dreaming up fun ideas for projects. We are lucky enough to find funding for many of them like with this nightclub where this was constructed. We also collectively use CNC routed products extensively, but always outsource those. Having a CNC router and AutoCAD would be the most amazing catalyst for us and I can guarantee would result in some genuine advancements in our creative endeavors. - speaking as humbly as I can; collectively, I don't know of a more deserving group. Now onto the Instructable...
This is a custom chandelier designed and built for Chicago nightclub, "Nikki", formerly Crobar. It was built on the request for a more permanent structure based on a similar installation I designed and built from large mylar balloons. See the image of the gold metallic chandelier .
This "chandelier" is 13' in diameter. Built from 126 Mirrored hexagons. 90 white framed hexagons.
Lighting consists of 126 small light bulbs in 12 channels and a trio of color changing LED fixtures.
With the exception of the steel hoops, which we had outsourced, this was designed and built entirely by myself and fellow Instructable maker, Sean Hunt. The finished result is especially spectacular in person, as the reflected surfaces and negative spaces really mess with your mind and it becomes difficult to really understand what you are looking at. :-)

Before I begin, here are all the detailed specs for the materials used in this project:

Large outer ring of hexagons made from 1/2" white ULTRA BOARD (polystyrene faced foam board), routed to aprox. 26 1/2" wide.
5 interlocking hexagon rows tall  (83 total)
12' 5" diameter, 39' circumference, support pipe is 1" welded steel made from 3 segments of bent pipe.
13" spacing of each vertical strand. 3" space in between each hexagon.
drop ceiling hang wire was used to suspend everything on this outer ring:
25 1/8" , 22 1/2" on top. (not counting bend and any hang over) 18: 30 1/4", 18: 7 3/4"
43 lbs total weight.

Smaller inner ring of hexagons made from 1/2" black/polished aluminum ULTRA BOARD (polystyrene/aluminum faced foam board), routed to aprox. 18 3/4" wide.
7 interlocking hexagon rows tall (126 total)
9' 8.5" diameter, 28.5 ft. circumference, support pipe is 1" welded steel made from 2 segments of bent pipe.
9.5" spacing of each vertical strand. (3" space in between)
Each vertical strand is wired together with 18/2 guage black lamp cord, hot-glued into place, running vertically over the center, and with a C9 lamp socket fit into the center hole of the hexagon.
Sockets and bulbs from actionlighting.com:
2 rolls of 250 ft. long 18/2 gauge black lamp cord were used to support and wire these hexagons.
107 lbs. total weight.

3 DMX Dimmer packs were utilized to control theC9 bulbs, in 3 identical sets of 12 channels. I used 3 compact units from Elation/American DJ:  DP 415

1' 8"+ spacing between inner and outer support pipes
8 1/16" steel cables hung from each pipe hoop to the center hang point. We used a 1/2 ton chain hoist.
The cables were measured to permit the outer hoop to hang a bit higher than the inner.

Step 1:

Step 1:  Choose a shape to work with and decide how big you want the chandelier to be.  We chose hexagons which create a honeycomb pattern but you could use any repeatable shape. Once you know the circumference of your structure you can divide it to find out how may individual pieces you will need and what size they should be. Since we were making 2 concentric cylinders of different sizes we did this with both.
I want to build this in my house... but my house is too small! I like!
I know, right? Not too many places you can build something like this! Glad you like it!
What happened to the previous chandelier?
The shiny gold one? I built it from gold mylar balloons. It was only temporary.
I <em>told</em> you it would be better as a step-by-step!<br><br>;-)<br>

About This Instructable




Bio: I've been self employed most of my life, with the curse of a seemingly unending stream of ideas. One of my best skills is ... More »
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