by:
Paul Lewis
photos: Bert Klassen
illustration: Len Churchill
CORDLESS BUG LIGHTS
Give
bugs the citronella kiss-off while casting a warm glow on your
outdoor activities
There’s something magical about the warm glow of candlelight
on a summer evening. It’s even more impressive if it is the
flicker of citronella candles convincing bugs to go somewhere
else. The frosted glass on these lights came from a stained
glass supplier, but you could use standard window glass.
Making the Wooden Bits
You’ll
need 18" of 1 x 6 cedar for each light. I started by using my
planer to dress the boards to 1/2", but this is optional. Before
ripping the wood down to 4"-wide, cut a 1/4"-deep kerf centred
on one edge; ripping this edge off at 1/2" will give you the
material for the glass trim. Now rip the boards to 4"-wide and
crosscut the base to 4" and the sides a little over 6"-long.
Lay out the 4" radius curve on one of the sides, using a compass
centred 2" from the bottom. Clamp the sides together and cut
them with a jigsaw just outside of the line you marked. Sand
down to the line while they’re still clamped together. To make
the slots that hold the glass, set the depth of your tablesaw
to 1/4" with the fence at 3/8". Test fit a scrap of glass in
the slot—you may need to make a second pass with the fence adjusted
slightly if the kerf of your blade is too narrow for the glass.
Now drill the 1/4"-deep x 2" dia. recess centred in the base
of the candle holder using a sawtooth bit—which gives the candle
a flat-bottomed base—or glue some small blocks to the base to
keep the candle centred. Bring the sides and bottom together
using #10 biscuits and weatherproof glue. Line up the bottoms
of the base and sides to make the index mark. Don’t forget that
the base is raised 1/2" from the bottom end of the sides. When
everything is glued and clamped together set it aside while
you build the top.
Build the Copper Top
Round
off the corners of the copper roof using tin snips. To cut the
centre hole you’ll need to fold the square in half. Clamp the
copper in a bench vise at the 3" mark and bend it 90°. Remove
it from the vise and fold it over the rest of the way. Squeeze
it flat in the vise then mark and cut the centre hole. Unfold
it back to 90° and file down the edges. Cut the two 3" support
rods from the brass stock using a hacksaw, and file both ends
of each rod to 45°.
Putting it All Together
Once the glue has set up on the base and sides, drill a couple
of 3/16" dia. holes and set the roof supports in them. Put a
dab of flux on the top of each rod and where the rods meet the
roof. Centre the roof on the rods and solder the assembly together.
While this is a pretty easy soldering job you might want to
opt for epoxy instead. All that’s left is to slide the glass
into the slots and secure the trim pieces to the glass with
a bead of clear silicone.
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