Final assembly
Drilling the clamp hole
Opening and closing
(^5)
Fit a stainless steel hinge at one
end of the mount.
(^8)
Tidy up the edges of the clamping
hole with a sanding disk or a wood
file to give a good fit onto the tubing.^9
Offer up the light and drill two holes
in the top flange for small self-
tapping screws. I then fitted an angled
plate made from 1mm stainless steel to
the base, as shown, to clamp the light
unit to the mounting.
10
Disassemble and give the wood a
couple of coats of waterproof
varnish (I used Le Tonkinois) until you
have a satisfactory finish. Cut the thread
of an 8mm plastic knob thumbscrew
down to 38mm long. Reassemble and use
the thumbwheel to clamp the mount in
position around one of your sprayhood or
pushpit tubes.
2
I marked off
the centre
point on each of
the long sides as a
start point for a
25mm hole saw,
which makes a
neat start to the
hole. I then used a
drill stand and
vice, to ensure I
was drilling
straight and
square, around
25-30mm deep
from each side. TIP: Position the vice
handle against the drill pillar, as shown, in
case the drill grabs.
6
At the opposite end to the hinge,
measure in approx 35mm on the
centreline and drill an 11mm hole through
both boards. Countersink the hole on the
light unit side for an 8mm Rivnut (an
ordinary nut would do) to sit flush with
the surface, and epoxy it in place.
3
Break out the core piece left by the
hole saw using a screwdriver.
(^7)
Drill a 25mm hole through the front
piece so that when the light unit is
mounted on it you have access to the
light’s switch settings. Fit a 10mm penny
washer over the 11mm hole on the
reverse side and secure it with epoxy.
DIY SOLAR LIGHT
4
Change to a 25mm flat wood bit and
continue drilling from both sides, to
create a hole all the way through.