Seedling Light Stand, Part 3

OK, so I have the new light stand about half assembled.  The 2 bulb fixtures were 1/2" longer than the shelves.  I was thinking "4' light fixtures, 4' shelves with the supports on the outside, should fit".  I should have checked more carefully.  But it wasn't as if I was going to buy more light fixtures, so it didn't really matter.  I had to attach them a little lower than planned.  The fixtures have attachment holes in them, but I had to partially take them apart to get at them and drill though-holes so as not to drill the insulation off the wires inside. 

The 4 bulb fixtures were easier in one way.  The wires were channeled around the attachment holes.  On the other hand, they were designed to hang from hooks on chain.  So I needed to drill a hole through the fixture anyway.  I ruined a drill bit trying to drill through what I thought was aluminum.  It was steel.  I should have checked with a magnet!  That was a bit from my REALLY GOOD set of bits.  I'll have to replace it.  I partially disassembled THOSE fixtures...  You may notice I keep having to do a lot of extra steps to make this project work.  I was not thrilled, but having started down this path, I have to continue.

So I got out my metal step-bit and the drilling went fine.  I reassembled the fixture and dropped in the bolts through the plywood.  Did I mention the plywood?  The rack comes with 3/8' pressboard shelves.  Strong enough for shelving or plant trays, but not much to drive a screw up into from below or countersink a bolt from above to support the light fixtures.  So I added 1/2" plywood below to hold the fixtures and counter-sunk the pressboard from below to cover the bolts.  It works great.  The resulting upper surface is nice and flat for the plant trays.  Looks good too. 

Here is the first 4-bulb fixture attached to the bottom of the 3rd shelf.  The top shelf will be identical.

Except...  You may notice a shelf support missing on the photo above (right side).  That's because one was 2" too short!  The box came with an information sheet asking that I call the manufacturer before returning the product to the retail store.  My interpretation of that is "we make a lot of mistakes, please don't tell the store.  Well, gee, it is about all constructed.  It would be a lot of work to take it apart and the box it came in is all ripped apart.  I emailed them about the problem.

The emailed back that a replacement shelf support is being shipped for delivery in 7 days.  That's reasonable.  I would have preferred a UPS overnight shipment on principle, but all my seedlings  are outside now and the light stand is for next year.

Here is a photo of the plywood base I used and the fancy cover shelf.  The are the same size, though the angle makes it look different.

It's been an minor adventure - more than building a box and less than building a shed.  I seldom get to build anything to specifications.  I end up having to craft things by trial and error.  Drives me nuts.  I have the genes of an engineer and the talent of an art major!


Which reminds me, I need to replace the roof on the shed.  I didn't know about roofing paper 20 years ago, and now it leaks.  Time to redo it right.  That's on the list.  The really really long list of major "to do"...

The lesson here is that I should have built the light stand as I originally intended.  3/4' plywood, 6' high and 5' shelves with the fixtures simply screwed right up into the shelf bottoms!  Don't get me wrong, the new light stand will be great for decades.  But the original plan would have been easier and worked as well.

Live and learn...