Pacific Northwest Mini PLUS Wi f W k hWireframe Workshop Wireframe Workshop 2010.pdfWireframe Workshop • Designs – Identify Project • Obtain image(s) –Snaggu ff w Pictures

Pacific Northwest Pacific Northwest Mini PLUS

Wi f W k hWireframe Workshop

Mark Zembruski – ZmanMark Zembruski Zmanwww.woodinvillewonderland.com

Copyright Woodinville Wonderland 2010

Wireframes - Overview• The most versatile display feature

– IMHO (for what it’s worth)– Small - Big– Flat - 3 Dimensional

St d l Vi tt – Stand alone - Vignette – Suspended - Hung– Static Animated– Static - Animated– Signs - Characters– Enhanced with Garland - Any Light styleEnhanced with Garland Any Light style– “Virtually Anything Christmas” – Virtually Any Season or Holiday– Virtually Anything Period…………

4/25/2010 2Copyright Woodinville Wonderland 2010

Wireframes - Options• Buy frames with lights

– Good selection– Ready to go– Shipping Considerations

B b f• Buy bare frames– Customize color and look

W k ith V d f C t F• Work with Vendor for Custom Frames– Personalized frame to your specifications

Use options from above– Use options from above– Saves time or if you don’t have access to welder

• Spark your own• Spark your own– Full creativity


Wireframes – Custom ExamplesZ H ld S• Zmans Holdman Star


Wireframes – Custom ExamplesZ M F• Zmans Marty Fan


Wireframes - Vendorsl h k• Planet Christmas Links– http://www.planetchristmas.com/vendors.htm– 17 current vendors– Vendors I have used:

• Holiday Lights - www.holidaylights.com• Lori’s Lighted D’lights - www.lorislighteddlites.com

Ch D B h h d b h• Christmas Done Bright - www.christmasdonebright.com• Winkelbottoms – www.winkelbottoms.com

• Custom Framesd ll k f – Vendors will work to create your frame to your specs

– Ensure you fully understand the process, provide explicit details, photos, sketches etc…E APPROVE t ith d b f k – Ensure you APPROVE concept with vendor before work begins

– Approve completed frame before it ships Christmas Done Bright Lori’s Lighted D’Lights– Christmas Done Bright – Lori s Lighted D Lights -Winkelbottoms


Wireframe Welding WorkshopE i t • Equipment

• DesignsP tt T f• Pattern Transfer

• Types of MetalCutting / Manipulating• Cutting / Manipulating

• Welding• Cleaning / Paint• Cleaning / Paint• Clip – Zip – Rip• Light and Stringing Options• Light and Stringing Options• Advanced Wireframe Design Considerations• Supplemental Information


Supplemental Information

Wireframe Workshop - EquipmentE i t (N t ll li t d i i d)• Equipment (Not all listed is required)– Computer (optional)– Projector – VGA or Overheadj– Bolt cutters – Metal Chop Saw (optional)– Hack Saw– Planetary Roller (optional)– Bench Vise– Anvil & Hammer – Bar & Rod Bender (optional) – Grinder / Metal Files– WelderWelder

• Small 120V – MIG – Wirefeed – Shield Gas (optional)– Flexible Measuring Tape– String or twineg– Work area

• Welding Table, Workbench, Plywood/Saw Horses4/25/2010 8Copyright Woodinville Wonderland 2010

Wireframe Workshop• Designs• Designs

– Identify Project• Obtain image(s)

– Snag Pictures off internet websitesg u ff w– Catalogs / Magazines – Scan into image for computer projection– Coloring books– Hand drawings

• Pattern Transfer• Pattern Transfer– Using Computer w/ VGA projector or overhead projector

• Project onto surface covered with roll paper – Draw pattern onto butcher paperp p p

» Alternate to paper, is Plastic Table Cloth by the roll– Alternate – Re-create image using graph paper pattern

• Consideration at this point - Scalability of Design– Depending on light types, consider segment length and scale

d i di l S l i l f li hp g g yp g g

design accordingly. Start planning early for lights.– Measure Segments

• Use flexible tape measure to approx length of metal segments– String or twine is another alternative g

• Mark up pattern for reference– Write dimensions & notes right onto paper pattern


Wireframe Workshop• Types of Metal • Types of Metal

– Steel Rod ( Hot & Cold Rolled) • ¼” Primary Size for Wireframe Designs• Hot rolled easier to work with than cold rolled• Available in many sizes for other uses• 20’ pieces. Buy whole and cut to transport if needed• Main Frame, Connector & Support Pieces• Note: Smaller diameter 3/16” rod is acceptable for wire • Note: Smaller diameter 3/16 rod is acceptable for wire

frames. Consider frame size for flexibility and stability– Square Stock

• ¾” - 1”, etc….F d – Frames, Stands, Supports

– Angle Iron• ¾” - 1” – 1 ½”

– Frames, Stands– Bar Stock

• Standard Sizes– Connector Pieces, Supports

– Flat Stock– Flat Stock• Custom & Standard sizes

– Used with other pieces to make Stands, Supports etc….4/25/2010 10Copyright Woodinville Wonderland 2010

Wireframe WorkshopC tti / M i l ti• Cutting / Manipulating– Cutting

• Hack Saw• Bolt Cutters• Bolt Cutters• Chop Saw

– Work space consideration – SPARKS!– Let the saw do the work, don’t force it

M k l !– Make sure you wear goggles!• Grinder

– Manipulating• Lay up metal on pattern Lay up m ta on patt rn • Plan your pieces

– Weld Acute Angles where possible» 2 pieces to make angle (Star)

– Bend Obtuse AnglesBend Obtuse ngles• Mark feature start and end with Metal Pencil or Chalk

– Manipulate, compare, manipulate, etc,….• Wedge into vise, use muscle leverage• Pound on anvil with hammer• Pound on anvil with hammer• Use Planetary Roller or Bender• Screws in plywood to create jigs & set ups


Wireframe Workshop• Welding (Preparation) – SAFETY – SAFETY – SAFETY!• Welding (Preparation) – SAFETY – SAFETY – SAFETY!

– Prepare Area• If welding on plywood, keep bucket with water and towel handy• Use pattern underneath if needed

W ld i b f l h t' d• Weld in an open area, be careful what's around• Keep fire extinguisher handy – WELD BEADS WILL ROLL!

– Prepare Yourself• Welding Helmet

Gl• Gloves• Old clothes, long sleeves (You will get sparks flying)

– Prepare Welder• Proper wire, voltage, speed/feed, tips• Shielding Gas? Open regulator

– Be sure you turn off your gas when not actively welding it will seep out at a very slow rate when not used

• Ensure you have proper ground connection to piecePrepare Pieces– Prepare Pieces

• Clean metal oil / oxidation before bending (Creates better welds, less spatter)

– Acetone (Allow to dissipate)– Wire BrushW r rush– Sand paper– Shop Towels

• Use pliers, welding magnets, jigs, screws to hold pieces in place4/25/2010 12Copyright Woodinville Wonderland 2010

Wireframe Workshop• Welding (Execution)• Welding (Execution)

– Wire extended from tip, approx 1/4 – 1/3”– Tack to hold pieces in place

• Use Tip Dip to help with spatterUse Tip Dip to help with spatter– Work on seam or spot

• Flip if necessary– Longer seams when welding, will sound like eggs

f f d h g g gg

frying in a pan if set up and technique is correct– Once weld is complete - USE CAUTION!

• Welding occurs at several thousand degrees• Metal is very HOT and will remain so for a while• Metal is very HOT and will remain so for a while• Even short durations generate tremendous heat• Do NOT grab with bare hands!

– Clean Spatter with brush if neededp– Grind / file welds if necessary– Complete Welding and Assembly

• Perform the John Bullard Drop TestHold 3 4’ off ground and drop it!– Hold 3-4 off ground and drop it!

» Reveals weak joints that otherwise look good


Wireframe Workshop• Cleaning / Paint

– Final Clean with Wire Brush or Sand Paper/ Acetone– Allow to dissipate - DryAllow to dissipate Dry– Prime with Rustoleum – Depending on Item:

• Paint white or black (Rustoleum)Paint white or black (Rustoleum)– White will accentuate lights and frame– Black makes frame invisible

• Paint frame sections to match light colors (option)H l i h f d fi i i d i d i– Help with frame definition during daytime

– John Bullard perfected this method!– Use cut drinking straws to cover lights

• Powder CoatPowder Coat– Expensive – Usually seen on purchased frames– Requires finding vendor– Not Optimal for one frame at a time

N tt h ll d i t t ill t ll – No matter how well you prep and paint, rust will eventually show through, don’t get discouraged


Wireframe Workshop• Clip – Zip – Strip

– Light Clips are arguably the best method for Mini’s– Light Clips are arguably the best method for Mini s• Fastest and allows for easy adjustments• Make sure you get the right size, 1/4” or 3/16” • Perpendicular Clips can be found

– Zip Ties• Time consuming but sturdyTime consuming but sturdy• For Rope Light, this is the preferred method

– Suggestion - get a Zip Tie GunE n if s Clips in s m n d t s ti s• Even if you use Clips, in areas you may need to use ties

– Strapping Tape • Probably the least desirable methody

– Frays and crumbles over time


Wireframe WorkshopLi ht d St i i O ti• Light and Stringing Options– Lights

• Minis (M5’s) & Rope (Ford’s or Chevy’s – personal taste)• C6 C7 & C9’s can be used as well• C6, C7 & C9 s can be used as well• Mixture of lights leveraging coro (Hybrids)

– Minis, C7’s and rope all on same frame be creative– Stringing Minisg g

• Pick start point, move optimally for string length– Leverage bulb counts 25/35 – 50 – 100

» Especially required for LED usage (intermixable, replaceable)– Cut and extend light strings if needed– Swap out bulbs to account for different colors

» Or use clear mini/M5’s with Color Caps– Make sure you manage and secure extra wire between

sockets» Wrap / twist wire on frame or use zip ties» Wrap / twist wire on frame, or use zip ties

– Stringing Rope• Start with predominant color• Know minimum rope length for type being usedp g yp g

– Split/Splice and extend rope if needed» Assumes you know how to cut and wire rope light

• Avoid or carefully bend tight angles with rope4/25/2010 16Copyright Woodinville Wonderland 2010

Wireframe Workshop• Supplemental Information

– Equipment / Supplies• Check Harbor Freight for great deals

W ld Pl R ll B d A il – Welder, Planetary Roller, Bender, Anvil etc…• Roll Paper – Sam’s Club – Butcher Paper

– Alternative is Plastic Table Cloth by the roll » Allows you to keep your template permanently

Mi h l Eb f VG O h d P j• Michaels or Ebay for VGA or Overhead Projector– Metal

• Check the web or phone book– Metal Supermarket – Everett Steel – EMJ – Specialty Metal Supermarket Everett Steel EMJ Specialty

Metals – Tacoma Steel– Shop, shop, shop for pricing

– Calculations • Circle CircumferenceCircle Circumference

– Pi (3.14 x Diameter) » http://math.about.com/library/blcirclecalculator.htm

– Polygon Calculator» www cleavebooks co uk/scol/calpolyg htm» www.cleavebooks.co.uk/scol/calpolyg.htm

– Metal Chalk/Pencils & Tip Dip• Home Depot – Lowes – Welding Supply (Central Welding)


Wireframe WorkshopAd d Wi f D si C sid ti s• Advanced Wireframe Design Considerations– Consider how acute angle features will impact

stringing lights– Carefully plan movement if you are designing an

animated/multichannel wireframe• Be sure you consider how the 2 channels will have to

i t l t d i t th finter-relate and co-exist on the same frame.– Alternate Methods

• Combine Coro and Wireframe (Hybrid)– Zmans Rudy (Nose/Eyes)– Zmans Rudy (Nose/Eyes)– Bill Foley / Carrie Sansing - Father Christmas

4/25/2010 18Copyright Woodinville Wonderland 2010Used with permission from Carrie Sansing

Wireframe Workshop• Supplemental Information• Supplemental Information

– Clips• www.holidaylights.com/moha.html• www.bettyschristmashouse.com/lights/mini.htmy g• www.lorislighteddlites.com/light-accessories.asp

– Perpendicular Clips• Kellog Plastics - www.kelloggplastics.com/ - ask for Doris

R l bl LED t i (R li bl i t i bl l bl )– Replaceable LED strings (Reliable, intermixable, replaceable)• http://www.holidaylights.com

– Color Caps• Christmas Light Show - www.christmaslightshow.comChristmas Light Show www.christmaslightshow.com


Think ItThink ItWeld ItLi ht ItLight It

Thank You!

Mark Zembruski – Zmanwww.woodinvillewonderland.com


Pacific Northwest Pacific Northwest Mini PLUS

Wireframe Hands on Wireframe Hands on LabLab Project :D l B ’ h Darryl Brown’s Shooting StarsHow –To: http://christmaslightshow.com/doityourself/shootingstar.shtml/

Copyright Woodinville Wonderland 20104/25/2010 21

Workshop Project :Darryl Brown’s Shooting Stars

l d h f l Star template was created using this image file. Note : the Segment Line in red. We will be making 5

segments in this manner4/25/2010 22Copyright Woodinville Wonderland 2010

Workshop Project :Darryl Brown’s Shooting Stars

We will create 1 of these to be given away as a Door Prize at the end of the Mini


Wireframe Workshop - Lab• Template premade• Rod – ¼” pre-cut and cleanedp• Break project up into easy sections

– 5 – 18” Obtuse angle sections– Bend angle in vise

• Compare against templateG t 5 ti k d – Get 5 sections mocked up

• Hold down with angle iron– Set up welderSet up welder– Prepare area, self, project– Spark away

• Drop test (after it cools)


Documents

Pacific Northwest Mini PLUS Wi f W k hWireframe Workshop Wireframe Workshop 2010.pdfWireframe Workshop • Designs – Identify Project • Obtain image(s) –Snaggu ff w Pictures