1 PVC pipe, 4” or
larger in diameter (the pictured fixture uses 4” pipe, but the bulb extends
slightly above the surface of the pipe. Use a larger pipe to prevent this.)
1 PVC closet flange to
1 PVC end cap to fit pipe
1 Four foot fluorescent
shop light fixture
1 Four foot black light
1 Heavy-duty male
Heavy-duty electrical cord (at least 6
1 Can of flat black spray
½” or ¾” plywood, approx 24” x
5 ¼” x 2 ½” bolts
7 ¼” nuts
2 ¼” x 2” bolts
5 Med to large sized
castor wheels (optional), and bolts, nuts and washers for each
Sander (or sandpaper and wood block)
Table saw or handsaw to cut pvc pipe
¼” drill bit
Large drill bit (large enough to cut a hole for the heavy duty cord to pass
Pliers (or wrench for nuts)
Rubber mallet (optional)
and mark the center of the plywood piece. Start
a nail at the center point. Tie one
end of a string to the nail and the other end to a pencil.
The pencil should touch just at the edge of the plywood.
Draw a circle on the plywood, keeping the pencil upright and an even
tension on the string. Using the jigsaw, cut on the pencil line.
Remove the nail. If needed, sand the edges of the plywood smooth.
Spray plywood black.
Place the closet flange in the center of the plywood
circle. Using the holes in the
flange as a guide, mark the points on the plywood where you will need to drill
holes for the 2 ½” bolts. Remove
the flange. Drill holes for the
bolts. From the bottom, thread the
2 ½” bolts through the plywood and the flange.
Place a washer and nut on each bolt.
Use the screwdriver and pliers (or wrench) to tighten the nuts onto the
bolts. Spray flange black.
If you are mounting the optional castor wheels (pictured),
you may do so now. Follow the same
procedure as for mounting the flange. The
bolt heads should be on the bottom (wheel side) of the castors, with the nuts on
top of the plywood base.
Use the table saw or hand saw to cut the pvc pipe to be
about 56” long. Measure a
rectangular opening just large enough for your shop light fixture to slide into.
This opening should begin about 3” from one end of the pipe.
This will be the top of the housing.
Draw the rectangle using the marker.
You may need to drill holes at the four corners of the rectangle and use
these starter holes to insert the jigsaw blade.
Use the jigsaw to cut the rectangular opening.
(The pictured pipe is 4” in diameter and the opening is 5”w x
49”h.) Spray the pvc pipe black
on the outside only.
Remove the face covering from your shop light fixture and
locate the two mounting holes in the back the fixture.
With the fixture inside the pvc pipe, mark the location of the mounting
holes. Remove the fixture from the
pvc pipe and drill holes for the mounting bolts.
Use the remaining washers, nuts and bolts to fasten the fixture to the
inside of the pvc pipe, having the bolt heads on the outside of the pipe.
Use the large bit to drill a hole in the pvc pipe directly below the rectangular
opening (it should be at least 1 ½” up from the bottom of the housing).
Thread the electrical cord through the hole and into the light fixture.
Follow the manufacturer’s directions to make the electrical
connections. Replace the
fixture’s face plate.
If your extension cord did not come with a plug end, attach
one now following the manufacturer’s instructions.
Slide the pvc pipe into the flange which is mounted on the base.
Slip the cap onto the top of the assembly.
If desired, use the rubber mallet to ensure the pieces are completely
seated. You may wish to drive a self-tapping screw through the flange
and into the pvc.
Spray the cap black.
Place bulb in the fixture.
Plug in your new light assembly and enjoy!