Seedling Light Stand, Part 1

A while back, I mentioned I planned to build a better seedling light stand.  The current one has only a 2 fluorescent bulb fixture per shelf, and even with good daylight bulbs, I find the plants get leggy.  I found 4 bulb fixtures at a decent price and bought a couple, thinking I could put two 2 bulb fixtures on the other shelves.  I planned to make it entirely of 1/2" plywood, 18 or 16" deep and 5 feet long to easily accommodate the 4' fluorescent fixtures.  I planned to attach cleats to the sides to hold the shelves.  The light fixtures would be screwed right up into the plywood shelves.  The shelves would be spaced at increasing distances so that growing plants could be moved to shelves further from the lights as they grew.  Simple basic construction.

It was a good plan.  I wish I had followed it...

But I saw an ad for rigid steel frame shelving at a really great price.  It was 4' wide, 2' deep and 6' tall.  Sounded great.  The shelf supports were adjustable in 1" increments and the shelves themselves were 1/2" recycled material that could support 800 lbs per shelf.  I measured the 4 bulb fixtures carefully and measured the floor display model.  It seemed they would fit right under the shelves perfectly!  It promised "easy assembly" (which, for its original purpose, was true).  I bought it. 

It weighed a ton!  Well, not literally "a ton" but I couldn't even pull the box off the stack due to the weight and friction.  I had to get a store person to help.  The top box was broken open (probably items missing).  The 2nd was fine.  We got it on a flatbed cart.  He assured me that there were outside people to help me get it in the car.  I planned to take the box apart from in the car at home.

Needless to say, no outside person ever became available.  In fairness, they were there, but backed up helping other people.  I finally did manage to wrestle the box into the car.  I'm not weak, but I'm not a weight-lifter either.  Fortunately, I do know some simple mechanical principles...

But I should have known I was off to a bad start!

Next, assembling the stand...