This is how to make a 45" tall Christmas Star, lit or unlit.
Step 1: Materials and Tools
(3) 1" x 2" x 8' PVC trim board (Menards)
( I chose this instead of wood, no warp, no rot, no bugs, and was pretty cheap too)
(2) 50 light set ultra bright LED Chrismas light set (optional) (Home Depot)
Screws (Drywall - coarse, 1-5/8 long)
Drill - optional
Step 2: Construction
Cut (6) boards per attached drawing. (.pdf and AutoCAD attached included here - no extra charge!)
A. There are (3) unique pieces, 2 each
B. There are only 3 different angles.
Step 3: Sub Assembly
Joints shown. You can use PVC Cement, or screws, or nails to secure.
If using screws or nails, and you want to add the 'lights' option - offset these for the light location.
Note - I kept track of each segment while cutting with numbers taped on!
Assemble (2) sub-assemblies (right and left). I laid one over the other to align everything perfect before gluing.
Step 4: Final Assembly
Lay one part over the other, align and join together!
Note the horizontal bar overlaps each other!
There you have it! Note the lap joint on top, and the overlap on the horizonal piece in the center pentagon.
Step 5: Optional Lighting!! - Way Cooler Too!
Purchase your lights first! This will allow you to measure wire between bulbs, and plan your spacing.
I used Home depot 50 bulb extreme bright chrystal clear ecosmart LED string. (qty 2 -100 lamps total)
Using my "goesinto" button on my calculator, that gives me 20 lamps per point. I ended up with about 1-3/4 or so spacing between bulbs. Make a plan, mark locations and drill away. (I suggest double check on your count first!) I used a 3/8" thru drill, then had to add a taper from the back with a 'pinecone' shaped burr tool to fit the lamp socket. Test fit your lamps so the entire bulb protrudes, but not too far. Different bulbs or brands may require different holes.
Since I had (2) strings, I populated the star every other hole. This could be for a cool effect of lighting one or the other string, and still have a star shape. (Think TSO and a light sequencer) Also solves the problem of bunched up wires.
I started my strings on the lower point, my plan is to have the star up high, and feed electricity from below.
Step 6: More Wiring
Place both strands into the holes. I secured them with a goob of hot glue to keep everything in place.
The only area I had trouble with was the peak, I had to make a path for the wires, this was the only place it was a bit tight.
Light 'em up and enjoy!