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Construction Of The Frame

InstructionsDiagramExample PhotoExample PhotoExample Photo
 Construct left and right side frame by joining 1x 72" 80/20 extrusion to 1x 80/20 24" extrusion with a 5-hole T-Joining Plate, build two of these T shaped structures 
Add supports for left side of frame by joining 1x 45 degree 15 series support to the T shaped structure created in step 1.  The 45 degree supports have their own joints built in  
Add 5 hole corner bracket to what will be the back side of the left and right frame   
Add rear bracing by first taping the bottom 24" 80/20 1515 section.  Add a pivot nub to 
Add 5 hole T-Joining plate to the bottom of the frame at the same location as the vertical 72" piece of 80/20 1515 
Add corner gusset to the middle and top of the frame near the centerline of the holes you had cut in the glass.  Subtract 3/4" for the center line of the 80/20 1515 crossbar we will be adding.  
With both the left and right side of the stand complete, join them together at the bottom with two pieces of 72" 80/20 1515 acting as crossbars.    
Attach 2x 45 degree 18" or 12" supports to the inside of the two frames and against the bottom, center crossbar.    
Insert 4x 5/16 T-Nuts into the remaining 2 72" 80/20 1515 crossbars, latter these will support the glass.  With the side containing the T-nuts facing forward, mounting them as cross bars to the structure.    
Tap the top crossbar and top of the right and left sides of frame.  Add a right angle connector.   
At this point you should have a completed frame.  Stop to check all connections and make sure everything is secure and tight   
Attach the stand offs to the glass and insert a 2" 5/16-18 bolt and 5/16 fender washer on the outside.  We found it best secure them with super glue to they don't fall off during assembly. The insert of the stand off should be in the glass as to prevent metal on glass contact.  Standoffs may be sourced locally or custom stand offs easily fabricated from wood or plastic can be used.  If using the 3D printing portion of this project, the standoffs file is here:  http://www.thingiverse.com/thing:348064 
Lay the stand down and put soft material over the frame (such as a towel).  With several people helping, place the glass over the frame and secure it, making adjustments to the top cross bars as necessary. Bolt the glass to the frame, DO NOT OVER TIGHTEN
While stand is laying flat, attach casters and caster mounts to the bottom "corners" of the unit.  BE SURE TO LOCK THE WHEELS.  With everything attached, stand the unit up raising it evenly from the top corners. Be careful not to apply torsional force or twisting motions. 
Secure power supplies to the left or right side of the stand.  If using a 3D Printer you can download and manufacture the part:  http://www.thingiverse.com/thing:348049.  If you do not have access to a 3D Printer a block of wood can be easily cut and fabricated to the dimensions in the example photo.  The power supplies require two of these units, a lower and an upper.   
Secure the power terminal block to the frame near the power supply.  The power supply cables are short so a distance of no more than a few inches is suggested.  
Secure the 3D printed fuse block and fuse holders to the chassis.  It is of critical importance that none of the power leads can come in contact with the metal frame.  If you have no access to a 3D printer, a simple version of this mounting system can be created by using a wooden or plastic spacer of approximately the same dimensions.   
Mount the Dimmer Bracket to the frame.  Using heavy grade double stick tape, adhere the LED dimmers to the bracket. 

Using 16 gauge hookup wire, connect:

  • The power supply hot lead to the fuse holder using female spade connectors
  • Connect the hot output of the fuse holder to the power side of the terminal block
  • Connect the negative side of the power supplies to the terminal block
  • Connect a power lead to the power input of each dimmer
  • Connect a negative lead to the negative input of each dimmer
  • Connect a 12v 15 amp fuse to the fuse box
    
If using 3D printed components, manufacture a batch of LED Clips.  Slide clips onto glass.  LED strips can be inserted into the LED clips along the track lines.  Add strips for the length of each side.  It is possible to put LEDs along the bottom of the project but cleaning fluid drips can cause issues. LED Clip.m4vImage Added
Connect the LED strips to one another at the corners with the LED connectors. Image Added   

 

Schematic For Studio Lightboard Glass

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