Parts

The next figure and table shows the materials and parts list to make one stand.  We experimented quite a bit with the design, and you may find other layouts or materials that you prefer.  No power tools are required to make this light stand cart, but a few will greatly simplify fabrication and assembly.  Most of the mandatory tools can normally be found around the house: a sharp knife, screwdrivers, hammer, hacksaw, file, center punch and drill.  You will also need a number 21 drill bit and a 10-32 tap and tap wrench and cutting oil or substitute.  A high speed hand grinder with abrasive cutting wheels,  wire stripper, bench grinder, soldering gun, rosin core solder and an electric screwdriver will speed things along significantly.

You may wonder why we used 48" long bulb fixtures with shelves that are only 36" wide.  There are two compelling reasons, fiscal and functional.  48" fluorescent shop light fixtures are easy to find and inexpensive.  The same is true for the bulbs.  While 36" bulbs and fixtures are available, they are much more expensive and are not easy to find.  The functional reason for using 48" bulbs is to ensure that the plants at the ends of the shelves get the same amount of light as those in the center.  The nominal 6" overhang of the fixtures on each side of the light stand assures even lighting right out to the shelf edges.  If multiple shelves are made and spaced at four foot intervals, as is the case in our experiment, the lights from adjacent stands butt up against each other, approximating infinite line sources of light to the seedlings.

Parts List

1 Heavy Duty 4 shelf rolling Cart 72" x 36" x 18"
6 @ 2 bulb 48" Shop lights with suspension chains
12@ 48" 40 watt fluorescent bulbs (cool white)
4 @ steel electrical receptacle boxes
4 @ heavy duty three three prong receptacles
1 @ 8-15' Industrial grade 16 gauge grounded extension cord
1 @ 1/2 " opening strain relief fitting
12 @ S hooks 1 1/2 or 2"
Roll of Underground grade 14 gauge wire: 2 conductor plus ground
10' long  X 1/2"( interior)  Waterproof Flexible Plastic Conduit
4 @ straight flexible conduit fittings 3/4" wide X 1/8" thick mild steel strap material
2 @ 90 degree flexible conduit fittings 3@ electrical receptacle covers
8 @ stainless 1" 10-32 machine screws package of heavy duty nylon strap ties
1 @ steel electrical receptacle box cover 2 @ large wire nuts

              14 Gauge Wire                 Waterproof Conduit, Nylon Ties      "S" Hooks, Conduit Fittings

                                                       Receptacle Boxes, Sockets, Timer & Power Cord
 
 
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