Instructables

Making a Light Box, Version 2

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Picture of Making a Light Box, Version 2
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After making my first instructable, Turn Your 12V DC or 85-265V AC Fluorescent Light To LED, I dressed up the cheap/generic fluorescent fixture with a bamboo light box using L-brackets.  My RV has 4 of these fixtures and I only had enough scrap bamboo to do the one box.  Not wanting to spend $180 on another sheet of bamboo plywood, I decided to find an alternative.  I also wanted to try out my new toy, a Kreg Pocket Hole Jig.

 
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Step 1: Tools & Materials

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Tools:
Kreg jig
C-clamp
Screwdriver (I use a $15 corded drill from Harbor Freight)
Saw
Step Drill Bits
1/16" & 5/32" Drill Bits

Wood (I used 1x2 pine from Home Depot)
12 Self-tapping screws (I use the Kreg screws)
1 Acrylic sheet (I always go to Ace Hardware, where they cut it to the exact size you need and charge by the square inch)
4 Wood Screws
4 Nylon Spacers
4 Screw Covers
4 Screw Cover Bases
1 Switch (I used RadioShack #275-648)
Wire
Frosted Glass Spray (I've included photos of the two products I've used; either works)

Step 2: Measure & Cut Wood

Measure the light fixture you are covering up and cut your wood to be slightly larger when assembled.  My boxes were made with two 1x2s 6.25" long and two 1x2s 19" long, assembled for an overall outer dimension of 6.25"x20.5"x1.5".

Lay the pieces together in the way that they will be attached and make sure everything looks square.  I made four boxes, measuring every piece 3 times before cutting and still ended up with two pieces 1/4" longer than they were supposed to be.

Step 3: Drill Pocket Holes

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Use the C-clamp to clamp the Kreg jig in place and drill out two pocket holes in each end of the longer wood pieces.  After you have four end holes (two on each end), add two more oriented 90-degrees from the other four for attaching the box to the ceiling (see photo below).  Once you have both long pieces of wood drilled, attach them to the short pieces of wood to assemble the box.