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New shop lighting

3K views 24 replies 12 participants last post by  ardbeg 
#1 ·
New shop lighting

The nature of present day lighting has been irritating me for some time.

The standard in woodworking shops has seemed to be fluorescent lamps. I have a couple of those fixtures near the tablesaw. I don't care though, for the kind of light at the work and I don't like the cost in energy. Lately I've been all worked up about being green.

I really would like to see some advancement in LED lighting, but I haven't seen anything that seems practical and I'm running short on time to work out something myself.

Yes, I have the background and tools to do that, but not enough time, what with everything that's going on.

A new development has spurred me on. I had a new overhead door installed, and unlike the old one, there were no windows in it.

Result: a black hole in that end of the shop.

So I determined to use present technology to get a better result.

CFLs are a pretty good interim technology and the costs are coming down while quality and efficiency seems to have improved greatly. So I decided I wanted to use that approach.

But I don't like the idea of having about half the light absorbed by the reflector in a standard fixture. Redesign!

So I built a prototype with glass mirror reflector panels. In it are two very bright 26 watt CFLs

Like this:


I had to be careful about size because there's only 7 inches clearance above the OH door when it opens.

So the result:
The shop with only the fluorescents above the tablesaw.



And then the new lamp is lighted:



I'm more than satisfied with the results. The light quality is more like daylight, and that should help when finishing. It is more light than I'd get from a 2 tube 4 foot fluorescent fixture. And, the total power load is 52 watts.

I think I lke it.

At least until we can have some good LED fixtures.

Don
 
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#3 ·
As my eyes get older I realize as some of you have I'm sure that good natural light or good artificial lighting can really help. In the shop I've got mucho lighting. It's everywhere. I planned it that way. In my shop I don't have old eyes. I can actually see the little numbers on my incra rule. Nothing more frustrating than guessing at a measurement and hopng you're right.

It looks like you've found a solution for yourself. Interesting.
 
#4 ·
Great job Don!

I've been a sucker for LED technology for the last 25 years but it is only now that they are becoming widespread.

Actually there are some good LED light panels out there. The only problem is, of course, the price. check these out, they are color calibrated and stable, widely used in TV sets.
 
#5 ·
I have found that a mix of both types works best for me. The florescent lights give area lighting and the CFLs give more concentrated task lighting. I find the CFLs alone are too intense and create stark shadows. But in combination with the others, the florescents tend to soften the CFL intensity and wash out the shadows.

Least ways, that's my very un-scientific belief.

But I really like your reflectors, Don. My CFLs are just in open ceramic screw-in base fixtures. I just might have to invest some time and make me some of those, I like the idea!
 
#6 ·
The reflectors were cut from cheap mirrors bought at Kmart or Walmart.
You will have to have a good glass cutter, though. If the cutting wheel slips the cut con't break on line.
Don't ask me how I know that! ;-)

By the way, this combination of two lamps and five mirror panels make for a sort of diffused light. If you look into the fixture it's like you're seeing eight CFLs!

d
 
#8 ·
Good idea Don,
I do have 1 question, Did you use any heat relief vents in the top of the reflector?
I tried using a reflector of metal and didnt think about venting it, so what happened was the base of the cfl became yellowed and soon stoped working. I made two of them and checked the other cfl after being on for about 20 minutes and it was very hot.
After venting them they have yet to burn out and its been months now. Oh btw Lowes carries a 300 watt cfl and it uses about as much as a 60 watt incadesent bulb. You want light they give you lots of light on the cheap.
I think I will try your idea thanks.
 
#9 ·
Jim,

These CFLs don't make very much heat. I didn't make any vents because of that.
Besides, glass mirrors probably won't go bad if they get a little heat.
But, time will tell won't it?
 
#10 ·
Don,

I think Jim, is saying since heat rises and these bulbs life decreases greatly when they get hot, have you provided any way for that heat to escape from the reflector…sameway if you put a CFL in a typical globe enclosure it will probally only last a year or so even with small amount of use (like a pantry closet).

Don't ask me how I know ;)
 
#11 ·
Well, I guess we'll see.
Its too late to do any venting without major surgery.
I dated the installation, so I'll know exactly how long the CFLs last.
This is only a prototype.
 
#12 ·
Very interesting innovation. Isn't innovation the way we make progress? I've been reading this thread with interest as I am having a similar problem with declining eyesight (age related) and have suddenly had to resort to reading glasses or a magnifying glass to read smaller print or to read the small markings on a tape or ruler. Being someone that has never required glasses or lenses it is quite an inconvenience/problem. I find though that the more light available…the better I see and it also somehow even affects my mood in the shop (considering Seattle has a higher suicide rate - this is theorized that it is due to them having more dreary overcast days - it somewhat makes sense to some degree - but I will leave that to the theorists).

That said, I am researching ways of strengthing the light in the shop…and putting in a few skylights in the darkest areas. I have already installed windows in every wall available (which does cut down on my storage area available - a trade off I suppose). This appears to be another tool in the arsenal…..

Oh, and if you tend to lose pencils and straightedges in your shop….add magnifying glasses and or reading glasses to that….I seem to always be chasing them…LOL..
 
#13 ·
Great idea Don but what I want to know is " were are the sketchup drawings for this fixture? " :) I my be stopping by Kmart this weekend for some of those mirrors, I know I could use some better lighting in my workspace.
 
#14 ·
Paul,
I didn't work it out in SU. Being the impatient, impulsive kinda guy I am, I just worked out a drawing for the mirror cuts and then played everything else by ear - er- hand - or - whatever. ;-)

Here's the mirror cutting diagram:



OK?
 
#16 ·
I've finally learned how to make a reflective surface and light sources, thanks to DaveR.

So here's my latest photo rendering of the CFL ceiling lamp.

 
#20 ·
Update:
I have converted two four foot 2 tube fluorescent fixtures in my wife's place of business.
I'm using 1 mil Mylar reflecting film to line the reflector panels and four 15 watt CFLs.
After gutting the fixtures of their old sockets and ballasts I install the standard lamp sockets in a horizontal position two facing this way and two facing the other way. The mylar film is simply attached by double faced tape.
The newly configured fixtures now draw 60 watts as compared to the 96 watts the old configuration drew.
Not only is it an energy savings, but the light is much brighter and of a better quality. The CFLs are specified to be Daylight in color.
They are so good, we intend to convert all her lamps.
I have only one more to convert in my shop.

The film is cheaper, lighter, easier to cut and affix. The reflective qualities approach those of glass mirrors.

d
 
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