Singing Pixel Snowman
Building on the method I used for the StarFlake Spinner, I am adding two 7' Singing Snowmen to my Display.
Bill of Materials
Polyethylene Coil 3/4" 100 PSI pipe - (approx 20 Feet)
3/4-in Dia Coupling Plastic Coil Fitting (3)
2" Sched 40 PVC Pipe - (10 Feet)
2-in x 1-1/2-in dia PVC Schedule 40 Double Sanitary Tee Fitting - (1)
2" dia PVC Cap Fitting - (1)
2" to 3/4" PVC adapter - (2)
ProConnex 3/4-in EMT Connectors - (2)
Metallic 3/4" Emt 10-ft Conduit - (10 feet)
Boscoyo Pixel Strips - (approximately 6)
Boscoyo ChromaTrim - (2)
Zip Ties - 4" - hundreds, 8" - a lot, 11" - more than you might think
Boscoyo ChromaFace - (1)
Boscoyo ChromaHatMatrix Small - (1)
I started my design by creating a Custom Coro face and hat, I worked with Boscoyo Studios to have these produced. They now have both available on their website the ChromaFace [1] and ChromaHatMatrix Small [2].
I then built two spinners using 3/4" ADS plastic water pipe 100 PSI, and Boscoyo Pixel Strips. The head was designed to be 18" (also surrounded by ADS pipe), spinner 1 (middle section of the body) to be 24", and Spinner 2 (lower body) to be 30" in diameter each. When you are calculating the circumference for each section of pipe keep in mind the formula C=π*d calculates to the center of the pipe. If you want the opening to be 18" exactly, you need to calculate for a circle of 18 + dia of pipe, or in this case 18.75", 24.75", 30.75". This requires the ADS to be cut to 59", 77.75", and 94.25" approx. Each length of the tube is joined into a circle with the Coil Pipe Coupler. I found it easier to heat the ADS with my heat-shrink gun to expand it slightly and ease installation of the fitting, however, care needs to be taken not to overheat the pipe and have it lose its shape and strength. Once the hoops are formed install the ChromaFace in the smallest hoop. I simply drilled 1/8" holes in 4 places around the section of pipe and in the CoroFace and fastened them together with Zip-ties.
For the Spinners make sure the hoop is close to round. Layout a section of Pixel Strip with one hole centered in the hoop and enough strip to wrap around the pipe on both sides, this will be your cut length for the rest of the pixel strips for that spinner, cut 7 more strips to this length for a total of 8. I found it best to find the center of all 8 pixel strips and insert a bolt through them all with a nut to hold it in place. This simplifies the process of mounting the strips on the hoops by keeping everything aligned and held together.
Zip Tie the strips to themselves around the hoop on each end. Care must be taken to NOT OVER TIGHTEN the strips on the hoop, or you risk deforming the hoop out of a flat plane. I also drilled 1/8" holes through the ADS pipe and Pixel Strips to create any anchor holes that I needed. I found it best to loosely attach ALL the pixel strips until everything was attached, then to work my way around the circle tightening being careful not to overtighten.
Both the Pixel Strips and ADS Pipe held their strength and shape nicely when being drilled multiple times in the same region, do not be afraid to drill either of these materials to create anchor points.
Once the Spinners and Face are constructed it is time to install the pixels in each section; Hat, Face, Spinner1, Spinner2. Each section had its own challenges.
I planned on laying the Hat over the top of the Face, but the hat was drilled for bullet pixels and I wanted to use square pixels to minimize their profile on the back, so I got out my spade bit and drilled out the back to work. I also ended up using a sharp chisel to clean up the back side of the coro. Not wanting to drill out the entire Hat, I switched to bullet pixels after the 1st two rows.
The Face had the pre-drilled holes for the mouth and eyes, but I also wanted an circle outline. I decided on a base of 24 evenly placed lights around the ADS hoop surrounding the Face. I then eliminated the top 5 pixels, as that was where the Hat was going to be attached. So I had a circle of 19 pixels going from approx 1 O'clock to 11 O'clock on the hoop. I used bullet pixels in the coro for the mouth and eyes and switched to square pixels again for the outline due to the lower profile.