Introduction: A2 Overhead Corner-LEDs Lightbox - Softbox Extension

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This documents the build of the softbox extension of the Instructable here. It consists of translucent, slightly reflective panels enclosing the light box and 2 or 3 halogen work-lights positioned outside pointing in. The panels utilize iron-on interfacing for the fascia - translucent and a slight shine (from the iron-on glue) on the inside. The work-lights are 150W lamps, but use a "Ultra White Light" tungsten halogen lamps.

I considered enclosing the gap from the lamps to the panels in reflective material but decided access to the lamps (for adjusting intensity) was more important. The lightbox and the lamps are meant to be placed on a table approximately 1200mm x 1800mm area (or on the ground). When not in use the lamps can be stored on the lightbox.

This version is "quick and dirty" - the panels are affixed using cable ties and are not easily removed.

Step 1: The Materials

  1. 3 off 150W Portable Halogen Worklight [buy]
  2. 3 off Ultra White 150W Linear Halogen Globe [buy]
  3. 2sqm of Interfacing (1600 grade)
  4. 11 x 11mm 2.7m Finger Jointed Pine [buy] (choose straight pieces)
    1. 6 off 425mm
    2. 4 off 500mm
    3. 2 off 570mm
  5. 12 off 100mm cable ties
  6. 12 off 150mm cable ties
  7. 12 off panel corners [print] [buy]

Step 2: The Tools

  1. Drop-saw or saw with miter-box
  2. Drill press or drill
  3. Drill bits
  4. Hammer
  5. Staple gun
  6. Scissors
  7. Utility blade
  8. 3mm diameter Spike

Step 3: Assemble the Panel Frame

  1. The upright timbers are 425mm long - affix a corner to each end by doing the following:
    1. Place flush with upright or bearing timbers.
    2. Mark holes.
    3. Drill holes.
    4. Cut grove between holes on outside of timber (careful).
    5. Fasten through holes with 100mm cable ties.
  2. The side frames horizontal pieces are 500mm long - affix a corner to each end by doing the following:
    1. Place second timber flush with outside of an upright timber.
    2. Mark holes.
    3. Drill holes.
    4. Cut grove between holes on outside of timber (careful).
    5. Fasten through holes with 100mm cable ties.
    6. Staple two timbers together.
    7. Repeat for all corners.
    8. This will give you 2 frames 500mm x 447mm.
  3. The back frame horizontal pieces are 570mm long - affix a corner to each end by doing the following:
    1. Place second timber flush with outside of an upright timber.
    2. Mark holes.
    3. Drill holes.
    4. Cut grove between holes on outside of timber (careful).
    5. Fasten through holes with 100mm cable ties.
    6. Staple two timbers together.
    7. Repeat for all corners.
    8. This will give you 1 frame 570mm x 447mm.

Step 4: Cover the Panel

The same process is applied for all three frames:

  1. Ensure the frame is square (equal diagonal distances).
  2. Cut a piece of interfacing 42mm larger in both directions.
  3. Cut a 21mm square piece out of each corner (slightly obtuse).
  4. Place the frame on a table (staples down).
  5. Place the interfacing on top of the frame (heat glue side down) square and evenly.
  6. Heat an iron on 3/4 heat with no steam.
  7. Keeping creases out, spot heat the corners to "set" the interfacing.
  8. Slowly iron each side until the glue has melted and adhered.
  9. Place the frame on the edge of the table and starting at 45 degrees iron a crease into the interfacing, increasing the angle until the interfacing is melted and adhered to the outer edge. Repeat for all sides. Yo may need to stand the frame upright for the last three sides.
  10. Turn the frame over so the unfixed interfacing is pointing up.
  11. Repeat the step 9 for the stapled side
  12. All three frames should have the interfacing fixed to three sides of the timber with the inside edge being left bare.

Step 5: Affix the Panel

The same process is applied for all three panels:

  1. Spike a hole in the four corner at the closest point inside the ABS corner.
  2. Place the panel against the frame side sitting on scrap 12mm MDF as a spacer.
  3. Affix the panel to the vertical pipes using the 150mm cable ties.
  4. When on the side with the bulkhead connector adjust the screen so that the power supply can be plugged in.
  5. Cut all the access off the cable ties, after they are tensioned satisfactorily.

Step 6: Preparing the Lamps

  1. Replace the standard globe with the Ultra White globe.
  2. Be careful not to use exposed fingers on the bulbs - the oil on the fingers can impact on the heat and light qualities. Use gloves or a material cover.
  3. Space the lamps on three sides about 400mm from the panel.
  4. If possible direct the center of the beam to the center of the panel.