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Step 4Diffuser option #1
SUMMARY:
This option for making the light diffuser uses reclaimed materials, and shows methods of work for mitigating the waste products.
DETAIL:
This diffuser uses PVC corrugated roofing.
My neighbour had put three sheets out for the trash, so I scooped them up!
This stuff also comes in colours and different profiles, so don't hesitate to try whatever becomes available.
The first task is cut the diffuser panels to size. A diagram (and PDF file) show the dimensions and mounting hold locations. Cutting with tin snips is easy and clean.
NOTE: my sheets had corrugations spaced 2.875" apart. If yours is different, you may need to adjust the width to get a flat fit to the aluminum mounts.
After some experimentation, I have arrived at a way to effectively diffuse light, and to minimize the creation of PVC dust particles.
Since the product's MSDS sheet doesn't state the dangers of exposure to dust, I have decided that it would be wiser to avoid the dust as much as possible.
To turn the original transparent sheet into an effective diffuser, the surface must be modified.
I used a wire brush mounted in a power-drill to do the bulk of the work of scratching the surface. It is possible to create patterns on the surface, by controlling the direction of the scratches.
PLEASE NOTE: I ran my variable-speed drill at low speed; this created heavier PVC granules instead of fine airborne dust!
The second step in modifying the surface was to wet-sand with 220-grit paper. This adds a necessary layer of diffusion to the surface.
Ideally, you should collect the water and PVC slurry in a tub, let the water evaporate, and send the residue to landfill. Otherwise, the PVC slurry will go through the sewage system and end up in your waterways.
(I mention this because it is in the spirit of minimizing all impacts.)
You are now ready to drill holes along the narrow edges to match the holes in the aluminum mounts.
I suggest practicing on a PVC scrap before performing the task on your finished pieces.
Some plastics will crack and shatter under certain conditions, and drilling holes to avoid this takes a bit of care.
I found that running the drill slowly with a minimum of pressure was gentle, but still effective at cutting the hole.
Be sure to make a little pilot divot, similar to that used for getting accurate holes in the aluminum.
Now its ready to attach.
This option for making the light diffuser uses reclaimed materials, and shows methods of work for mitigating the waste products.
DETAIL:
This diffuser uses PVC corrugated roofing.
My neighbour had put three sheets out for the trash, so I scooped them up!
This stuff also comes in colours and different profiles, so don't hesitate to try whatever becomes available.
The first task is cut the diffuser panels to size. A diagram (and PDF file) show the dimensions and mounting hold locations. Cutting with tin snips is easy and clean.
NOTE: my sheets had corrugations spaced 2.875" apart. If yours is different, you may need to adjust the width to get a flat fit to the aluminum mounts.
After some experimentation, I have arrived at a way to effectively diffuse light, and to minimize the creation of PVC dust particles.
Since the product's MSDS sheet doesn't state the dangers of exposure to dust, I have decided that it would be wiser to avoid the dust as much as possible.
To turn the original transparent sheet into an effective diffuser, the surface must be modified.
I used a wire brush mounted in a power-drill to do the bulk of the work of scratching the surface. It is possible to create patterns on the surface, by controlling the direction of the scratches.
PLEASE NOTE: I ran my variable-speed drill at low speed; this created heavier PVC granules instead of fine airborne dust!
The second step in modifying the surface was to wet-sand with 220-grit paper. This adds a necessary layer of diffusion to the surface.
Ideally, you should collect the water and PVC slurry in a tub, let the water evaporate, and send the residue to landfill. Otherwise, the PVC slurry will go through the sewage system and end up in your waterways.
(I mention this because it is in the spirit of minimizing all impacts.)
You are now ready to drill holes along the narrow edges to match the holes in the aluminum mounts.
I suggest practicing on a PVC scrap before performing the task on your finished pieces.
Some plastics will crack and shatter under certain conditions, and drilling holes to avoid this takes a bit of care.
I found that running the drill slowly with a minimum of pressure was gentle, but still effective at cutting the hole.
Be sure to make a little pilot divot, similar to that used for getting accurate holes in the aluminum.
Now its ready to attach.
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Jul 25, 2007. 2:46 PMled_scorched
says:
You could also use steel wool or even a scotchbrite pad to make the diffuser
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