QUOTE (kariya762 @ Apr 1 2007, 08:30 PM)

got my first part today. venture ballast. its freakin heavy. don't know how heavy an average one is but this one weighs 10.5 lbs. hopefully i will get my bulb reflector triplet and base by tuesday.
Wow...that is heavy (a 150w-Sola MBall is a tad under 9, and I thought EBall's were lighter...?). [Or is it an EBall?]
I'm building-in added length fore/aft for 'eventualities' that you can easily cut-back later (owing to 'slide-back' nature of front/rear endcaps), but shoot-me dimensions of base-bottom-to-arc and ballast when possible.
Your sled, as discussed, will be 'substantive', and add some to width/height -- but I REALLY hope the small panel/case doesn't require a diagonal-mount to get arc-to-center (if we encounter that situation, I'd suggest cutting a base-size hole in PJ-side then space-out as required for a simpler horizontal-orientation for bulb/base).
Your PJ, however, should be very-small/very-bright...!
I hear elsewhere the Ushio has a shorter-arc than the current T-15-style...so that should-help PQ.
Unsplit should be best (but I'm planning-in a mount possibility for split, in case you decide-otherwise, later -- no 'dimensional-harm' in-that)...
EDIT: No-way that Ushio is gonna mount horizontally...the smallest-measurement I found from mogul-base to arc-center is around 7.75", or even-more (for longer-ver.). This panel, plus even a 1-1/4" sled-side, would only allow for 6"-or-so. We can maybe go with a diagonal-mount (Ushio is a 'universal', anyway), if we 'squeeze' and you have the shorter-Ushio [but will you then be able to replace that-bulb with 'short', I think the newer-stock are the-longer?], or we can elect to add-width -- maybe only on one-side?
I think I'll just start with sled and cut only case-sides until you can figure-out this 'wrinkle' after 2:45...hopefully you'll have bulb/base by then -- but I believe that with this-and-similar lamping, we'd better-allow at least 8-1/4" base-to-arc-center (and that's from a diagonal-piece for mount, that has to be the width of that large-mogul -- these lamps are _monster_ compared to the teensy-150's! <g>)
As for length, the 320mmX2 plus 60-or-so for the frez-panel-area requires 27.5"-interior, so allowing an extra 5-6" for ballast/light-engine room takes you to 34" or less. Allowing for end-caps, I'm going to cut sides/top at 37" (more than enough, without much extra shipping-expense, and you can shorten as desired after you complete your design/tests/final-measurements).
Outside case-height will be 9" (unless you want more for 'bulb-room'?).
So--we still have 'details' to discuss...
[From PM:]
QUOTE
yes i do like the 120 mm intake. the lengths you mentioned for the dimensions are fine. The bases diameter is 2 inches and its 2.5 inches long. The 7 inches i mentioned is actually about 6.9 or so to the center of the arc its really close.Just tally up money and when i should pay you. I'll be on the computer tonight if you need me. My excitement for building my pj has been brought down by the lamp and bulb. don't really know how to wire it or to figure out how i would power it/ turn it off and turn it on.
I'll walk you through the entire-process...don't be 'down in mouth' about lamp (although it is a whopper...it should prove VERY bright, and relatively cheap-to-replace and long-lasting). Also, the arc is relatively-short for a 400w-er, and and color-quality is OK...
Wiring is not as involved as you'd imagine...you'll basically have a master-switch (which turns-on the 12v fan/controllers/panel), and another-switch that turns-on ballast>lamp...the order reversed when turning-off.
Many Plogs at LL detail the wiring-options...
We'll discuss all-this in your plog after-delivery.
I already sent you a list of other/additional expenses (should you want pre-cons/etc. from me), and balance on mat./kit -- but until case is packaged/weighed, I've no idea what it will cost to ship (if it gets really-heavy, there is Watkins (where I have a commercial-account) or Greyhound -- but prolly USPS).
If you had answered my question about 'how base attaches' I could have easier-figured your diagonal-mount. Instead, I'll send you a stout/5" piece of pre-bent metal you can drill for base and mount with some 1/2"-screws (I think I'll also throw-in most of the screws you'll need for assembly, and pre-drill a lot of it). Glad you are OK with the length. I suggest you just paint interior with high-heat flat-black spray-paint and prime-only the exterior before using and finding perfect-positioning of case-front/triplet and finish all stuff in case-rear (then, lop-off the excess front/rear to end-caps, or within an inch of them -- which could be done 'assembled' on a table-saw -- if CAREFUL).
Then touch-up sanding/primer/paint when you have-time/incentive.
I have to assume that your replacement lamp will go perhaps 8-1/4" base-to-A.C. -- and you didn't answer re: asymmetrical-widening of box. So, I will make the sled, then add whatever spacer-stock is required on both-sides for a diagonal-mount of your-choosing later (the panel itself is only 9.5" X 5.75" -- so a teensy-case as you initially specified is possible, but that would crowd-everything and may be unsafe, and never be suitable with any high-lumen lamp...so your case (once I figure for the waste at a-corner to fit a 2"-base) will end-up with interior-measurements of about 14" X 10" or-so. Still very-small, as these lcd-PJ's go (and your final-length MAY be as short as 28" or-less -- depending on how cleverly you install ballast/shielding/fans/etc.).
I'll get an early-start. However, you also did not answer my questions about how Inputs will either be fed by 'pigtail(s)' and from-where, or controller poke-out case-side (and if-so, with daughtercard?). Given all-above, and need to get your approval AND your-payment for shipping-cost (and need for me to sorta 'crate' this mess so nothing is damaged en-route) -- it won't get mailed until at-least tomorrow. That should still reach you Mon., if not Sat. (and you'll PLEASE take your time during assembly and remaining-planning!).
You MUST be careful with positioning/shielding/etc. since these bulbs get VERY hot (and can set cases-afire or damage-panels if not ventilated properly). And, the voltage from a ballast/capacitor is VERY dangerous IF you really screw-up and/or grab the wrong-thing (even shortly-after unplugging-all). I want you to thoroughly discuss decisions/progress/assembly with us in your Plog after receipt -- and continue to involve your dad in this project -- as he has-been to date (as a 'double-check' for at-least those things related to your safety [even if he's uncomfortable cutting things like case-elements] and the safety of his-home!). People your-age and under build such-things on a regular-basis ... but some get 'over-eager' or otherwise 'pay-dear' (read Ziggy's Plog...he blew a grand). A PJ like this can last for years...don't sweat not being done by end of one school-break...someone your-age has 'nothing but time', and can afford to let many of us at LL help you avoid any unfortunate-mistakes...
In fact, now that you've informed me of your age, I'll want your phone number so I can confirm that your dad will be 'supervising' this over-all project -- and I'll ship to him. I didn't sell you the ballast/etc. nor encourage you initially to build one of these PJ's, but I want no liability later if he doesn't exercise appropriate parental-oversight "in eyes of Law". Don't take-offense, but sillier-stuff has hit courtrooms...believe-me...
[end quote]
Let's just continue correspondence in here...these PJ-discussions are helpful to others...after-all.
You _should_ be using 'time in interim' to read other-Plogs related to designing light-engines (mounts for pre-cons and reflectors) and placement/wiring/shielding of ballast/rear-fan/switches/wiring/grounding/etc. AND the safety-warnings found readily in LL...
And more:
So, I nearly finish your sled (played-around and ran 2X4 stock through a planer for 'truing') and figured thicknesses for spacing and secondary-frame for sled, then go to first-cut on plywood for case...and my tablesaw of seventeen-years (which, btw, I consider a 'pretty new tool' -- although it's older than some peeps I-know<g>) blows-up one of it's motor-brushes! [And I'm about 65-miles from anywhere with a good-selection of brushes (TraverseCity) and proper replacements are no longer made/offered). Had to go to town, find similar, remake my own brass brush-holder, modify the channels in motor for new assembly, and pretty-much blew the day. Sorry.
Tomorrow should be 'more productive'.
I will attempt to also make a mounting-plate for your controller-inputs--but it's going to be tight for cable-length from panel with daughtercard (which apparently you'll need, since you PM'd today about using/wanting Composite -- to see this controller/daughtercard, go to FAQ-page:
http://www.lumenlab.com/forums/index.php?s...d=222023&#). Punisher is the only-guy to create a custom-plate for external-Inputs...and he had to get a custom-cable to allow folding the daughtercard (a cable I don't-have)...I'll attempt a straight-across tomorrow--perhaps of opaque-plastic flush with interior ahead of sled-bottom (either interrupting or on top-of the 1X3/4 corner-bracing...).
This 'roughed out case' is getting a tad complicated...but it is sorta 'fun' (kinda getting into-it now). Your bulb will fit, and you'll be able to switch from unsplit to split (if you ever care-to).
Only 'problem' I see so-far is Carpow's polars (which are what you want...better than SHC's -- at least they are with lesser-bulbs...?), which have a sticky-face [good-thing], but which got some bits of sawdust on same [bad thing?]. I'll attempt to clean them...but you may want to order a new-set (especially if you end up ever doing frez-shifting and/or replacement, or go to 'split'). Fortunately, they are only 4. (as long as someone is ordering from Carpow anyway...and remailing is way-cheap).
I'll be shipping the sled with frez/panel installed, and sled sandwiched between/among case-parts (for safety during shipping). Priority shipping Thurs should get it there either Sat. or (more likely) Mon. I'll weigh the mess tomorrow and advise you tomorrow-night as to shipping-cost (15 lbs is a good-guess, so prolly around 19. to Ohio plus ins.).
It's 9:30...I'll check back around 10:30 to see if there's feedback/requests...or post in AM.