The best lamp I found, suited for wall mount, was conforming IP44. Obviously, this is not sufficient: it will be continuously exposed to harsh weather conditions (sun, rain, snow, frost, hail) during long periods (possibly days). Very short examination showed that rain can accumulate into the border of the solar panel's frame, and water will eventually seep into the panel. Also, continuous alternation of sun and rain/ice will lead the plastic case to become brittle and surely to eventually crack. I'm not an expert in this area, but I think it needed to get turned from IP44 to IP44W...
Then, I saw a very big plastic salad bowl, that would perfectly fit as a protective cap above the lamp. All this (plus the fact that my mum was urging me to improve the path visibility at night) was more than reason enough to start a new DIY project, so I decided to buy the lamp, the bowl, and a galvanized pole.
Step 1: The Lamp
- LED panel, 80 LEDs, totaling 6W
- PIR and sunlight detector, to detect beings at night
- Solar panel, with a surface largely surpassing these ridiculously small solar garden lights
- IP44 plastic case
- Three potentiometers to set: Night light threshold, lighting intensity, and lighting duration
Step 2: The Pole
Step 3: The Cap
Diameter: 34 cm (approx 13.4 inches).
Step 4: Needed Stuff
- PVC L profile
- Wooden stick, rectangular profile
- Scrap plywood
- Plexiglas (leftover from other projects), 2.4 mm thick
- Silicon sealant
- Various screws and bolts
- Galvanized steel perforated band
- Paint, suited for outdoors, and wood primer
Step 5: Fitting the Cap
I first made a cardboard model, then sawed the pieces out of scrap plywood.
After assembling with tenons and screws, I applied some wood primer, then several coats of yellow paint.
Step 6: Making the Solar Panel Mount
To protect the top edge I glued an L-shaped PVC profile onto the Plexiglas, so that the rain would not drip into the inner side.
Wood profile was used to build the yellow fixture, and has been assembled with the Plexiglas using screws and O-rings. The Plexi was sanded there, to allow the glue to adhere.
The orientation of the panel, relatively to the orientation of the LEDS, has been carefully determined. I marked the position and applied some silicon sealant between the panel's foot and the bowl.
Several holes cross the salad bowl:
- Four for the screws. Sealed by o-rings.
- One for the wire. Sealed with hot melt glue.
Step 7: Assembling Things
The pole came with a fixation brace, and a plastic cap (visible in Step 2). I screwed the brace and the plastic cap to the backside of the yellow board, and tightened the pole.
The cable could be bundled and attached using zip ties (you know how I like zip ties...).
Step 8: Installing and Letting It Shine
Then, after a few checks at night, the final place was confirmed. I attached the pole using galvanized steel perforated band.
Now it's doing its duty very well, undergoing a period of several days of uninterrupted intensive rain. The strong wind caused the rain to splash all sides of the lamp. The bowl's exterior was exposed to rain as if literally immersed into water, but not the lamp.
Let's see how many years the salad bowl (sorry, the cap) will stand the weather. Changing the bowl will be less expensive as the lamp.
The strange alien/robotic look does not miss to attract attention and raise questions!