Ken's 215G Build

JGT · Feb 1, 2021

kenchilada said:
Yep the rod is aluminum, cut to length. I’m using stainless derailleur cable, it’s literally what is used for bicycle brake cables and the same cable ATI uses for their fixtures. Once you one what to use, it’s almost too easy! Took me forever to work it out though.

Cool, how far will the lights raise up? And a single cable or one on each end. Assume your using something like an 80/20 aluminum t track to hold the lights. Sorry, I know I’m jumping the gun on your how-to, just curious.

kenchilada · Feb 1, 2021

JGT said:
Cool, how far will the lights raise up? And a single cable or one on each end. Assume your using something like an 80/20 aluminum t track to hold the lights. Sorry, I know I’m jumping the gun on your how-to, just curious.

No problem ask all you want, I love it!

I’m hanging a 60” 8x80w Sunpower, so one cable on each end. My Kessils are supplements and hang from those four wood bars across the front (goosenecks clip to them).

If I did LED primary I would either build a frame from wood or do 80/20, still with one cable on each end that attaches to front and back (Like an upside down Y).

I can lower the Sunpower to about 2” off the water and raise to about 14”. The reason it goes so low is there’s a hidden door in the side of the canopy (removable trim) so I can slide the acrylic shield straight out the side of the canopy to change T5 bulbs without removing the canopy!

JGT · Feb 1, 2021

Cool, yeah I’m doing all leds so planning to use the 80/20 t bar.so the rod takes one cable that splits into 2 at each end of the fixture. I would want more headroom than 14” but I guess that would simply require mounting the rod higher in the canopy, no? Smart idea on the acrylic trap door.

kenchilada · Feb 2, 2021

JGT said:
Cool, yeah I’m doing all leds so planning to use the 80/20 t bar.so the rod takes one cable that splits into 2 at each end of the fixture. I would want more headroom than 14” but I guess that would simply require mounting the rod higher in the canopy, no? Smart idea on the acrylic trap door.

Yeah if your canopy is tall enough you can raise it as high as you need, since the cable just spools. And technically only the pulleys need to be mounted at the needed height. The rod can be anywhere.

kenchilada · Feb 2, 2021

Lots more done. Got the pulleys mounted. Finished the canopy lid. I’m starting to fill holes and sand. Really want to stain it this weekend.

JGT · Feb 2, 2021

Getting there. So does the cable just spool randomly on the rod or is there some type of containment pieces on the rod that keep it confined to an area on the rod sorta like a fishing reel spool, if that makes any sense?

kenchilada · Feb 3, 2021

JGT said:
Getting there. So does the cable just spool randomly on the rod or is there some type of containment pieces on the rod that keep it confined to an area on the rod sorta like a fishing reel spool, if that makes any sense?

That was the hard part. Someone pointed me to a old thread on RC where the guy had a takeup reel, and I could never find anything like it. I posted a picture here and an awesome guy made this for me and 3D printed a pair. He posted the STL files... I can find them if you want. I have access to a printer at work now too but haven’t tried it yet.

The black reel is 3D printed...

kenchilada · Feb 3, 2021

More done today. Worked out the door system... I decided against hinges so the doors will have a cleat at the bottom and click into a frame magnetically. The dog-eared pieces below are where the magnets will be countersunk into.

Here’s my insane notes and sketches from this week...

JGT · Feb 3, 2021

kenchilada said:
That was the hard part. Someone pointed me to a old thread on RC where the guy had a takeup reel, and I could never find anything like it. I posted a picture here and an awesome guy made this for me and 3D printed a pair. He posted the STL files... I can find them if you want. I have access to a printer at work now too but haven’t tried it yet.

The black reel is 3D printed...

Very cool.

kenchilada · Feb 4, 2021

Any opinions if I should paint inside canopy white? Or clearcoat it with polyurethane?

I can’t decide...

JGT · Feb 4, 2021

Hmm, either would be nice. But thinking the white might provide additional reflective qualities for the lighting.

kenchilada · Feb 4, 2021

Cut holes for fans today. Six fans total, over 600 CFM.

Two fans are dedicated to cooling the Sunpower fixture through a vent box that catches the exhaust from the side.

There’s also a temperature controller that controls fan speed. These things are really quiet too!

kenchilada · Feb 4, 2021

More random pics.

You can see here how I’ll mount my Kessils from the ceiling on goosenecks.

driftin · Feb 5, 2021

Everything looks so clean, great build.

Which model fans did you use? Do they work without the controller too, for example if I was going to power them on/off via a different controller?

kenchilada · Feb 5, 2021

driftin said:
Everything looks so clean, great build.

Which model fans did you use? Do they work without the controller too, for example if I was going to power them on/off via a different controller?

Thanks for the kind words!

The fans are from https://www.acinfinity.com. You can use without the controller, they actually come with a slider switch to adjust speed on their own.