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  weekender  
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

bug lightsYou’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

bug lightsRound 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.

Click here to enlarge
You Will Need
Base 1/2" x 4" x 4"  1 
Sides 1/2" x 4" x 6"  2 
Glass trim 1/2" x 1/2" x 3 7/8"  2 
Roof - 18 ga. copper 6" x 6"  1 
Roof supports - brass 3/16" dia. x 3"  2 
Glass 1/8" x 4" x 4 1/4"  2 
Click on the image
above to enlarge it
 





 



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