I'm building my rendition of a haas styled box, squared corners etc out of mdf. I want to insolate the mdf from the light engins heat as much as possable. I figured a light box would do the trick. I was thinking about using 1/16 or 1/8 sheet mettle and build be a box the old fashioned way ( read: no CnC).

Couple of questions for those in the know:
A) which would you guys recommend for thickness, based on the heat from a 400w mh bulb and balast ( mega s15 kit),

in lieu of a spot welder do you believe rivets will hold up to the heat?

C) any designs from past plogs come to mind as a good place for inspiration? I have looked through them but may have missed a few, or more

Thanks again

Just thick enough to not be flimsy. Rivets are fine. I used them extensively building my lightbox. Check my ploD (signature line) and I apologize in advance for making you wade through the whole pile of poo to find anything remotely useful. But it'll be another 2 years before I get a "Completed Projects" topic so you must suffer for now!!

Edit: I would be remiss were I not to mention, once again, that SamuraiJack was my lightgate inspiration.

1. 1/16" sheet is overkill. 20-22Ga sheet is overkill. The light box in my pro lens projector is made from 22Ga sheet, with a couple of aluminium parts to hold the mogul socket, and C channel to mount it to the case. My latest start on a light box is 20Ga sheet, and it's defintiely heavier than it needs to be.
2. Mine is held together with screws, so rivets are certainly adequate. (Though I'll be welding the new one, just because I can.)
3. I'm pretty sure that I detailed my light box in my Pro lens PLOG. Other than that, SamuraiJack's PLOG is a good place to look for light box ideas (Probably more complicated than is strictly speaking necesary, but a good start nonetheless.) Simul8r and Durachko also have good light boxes. Theirs feature precondensers, as will my new one, which I haven't yet finished, so you can't look at it.

It struck me when reading Supra's reply I should have mentioned when I switched to the 575WHMI I found the ability to vent the lightbox directly to outside the enclosure invaluable. Even with the 400W I should have gone that route in hindsight. In order to do that though you'll need a "window" for the light to escape the lightbox. Any heat resistant glass of reasonable transmissivity/clarity should suffice but I chose to use a so-called hot mirror - heat resistant glass that reflects infra-red wavelenghts and some UV as well as a bonus. Something to keep in mind should you ever find yourself launching into pursuit of more lumens in the future. More wattage = more heat. More heat than I bargained for in fact!!! But all's well that ends well and I'm back on track.

Happy building and best of luck!!!

Generally I see a light box as a way to 'channel' the air directly to where you want it and in this case the arc and/or precon for that matter. More like a wind tunnel. Direct fresh flowing air over that heat source then exhausted out removes heat tremendously. Not saying that venting air between fresnels and lcd is not required when it definately is but at times I've seen exhaust fans placed in areas within a build that channel the air and miss the arc alltogether. In otherwords a concentrated flow has a better potential for heat exchange when directed at the source.

I see ok. I'll catch up[ on those plogs, and simul8r gave me a great idea, I'll spend some time try to draw it up

I used some 6" X 12" pieces of sheet metal I bought from Home Depot (I will have to double-check on that size) anyway, I bought some aluminum "L" angle from there and used this as a "frame" and pop-riveted this into a light box... took just a few hours to have a nice light box with my pro-reflector mounted on the back with the adjustments on the outside. I cut a round 4" hole for the light to come out of and I can mount a pre-condenser lens on that if I desire.
The nice thing about using a light box is you can direct the airflow over and around the lamp therefore keeping the inside of the PJ box a lot cooler.

Was looking around Johnzo's site - and am thinking about his box set.here
and I believe this would fit. I already have the mega kit coming - however I'm thinking if I find a precon would benefit the pj this seems like the way to go.

any thoughts?

I've got that lightbox from johnzo and it's very nice. It's been said, however, that the included precon is difficult to configure and some people choose not to use it as they get a better projected image without it.

http://www.lumenlab.com/forums/index.php?s...st&p=254159

As far as the bulb you chose, you might find that a 6500K bulb is too warm and produces a blue light. I would recommend either of these two bulbs, instead. They are a bit more expensive, but I think you'd be happier with the light output.

USHIO CMD-150/TD/942/RX7S

Satco CDM150/TD/942

I'm personally sold on the ceramic metal halides. See my PLOG link below for my choice.

Thanks

In closing this thread ( someone lock its dead) and will continue anything about the the light box in my plog.

I am going to design a box based heavily on Durachko who said he took cues from Samuraijack.

The design on D's lightgate will fit well in the back of my Haas - ish enclosure. I say Haas ish because well - you do what you can with what you have

Your wish, my command, etc.