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Discussion Starter · #1 · (Edited)
I've been trying to figure out how to make the top for lighthouses and saw a bird feeder that looked great. I took a good look at it, got home, and went to work.

It's 8 sided so I use a 22.5 deg angle on most things. I started by ripping some 1 by 4" poplar to make the side posts using the TS set to 22.5 deg making triangular shaped pieces. I then used my RT with a 1/4" straight bit to form a groove in each side after cutting pieces 6" long.
http://www.geocities.com/axlmyk/lighthouse2/rip_and_cut_the_edge_pieces.JPG
http://www.geocities.com/axlmyk/lighthouse2/rip_and_cut_the_edge_pieces.JPG
http://www.geocities.com/axlmyk/lighthouse2/Rout_the_edges.JPG
http://www.geocities.com/axlmyk/lighthouse2/Rout_the_edges.JPG
I then set my new Ridgid sander up to make a compound angle on the tops of the side rails. A jig made from cutoffs from the top pieces was used for the initial angle, then I adjusted the table to 33 deg. Just a slight amount was taken off till the sanding line met with the routed slots.
http://www.geocities.com/axlmyk/lighthouse2/Jig_from_scrap_to_sand_side_tops_to_13_deg.JPG
http://www.geocities.com/axlmyk/lighthouse2/Jig_from_scrap_to_sand_side_tops_to_13_deg.JPG
http://www.geocities.com/axlmyk/lighthouse2/Table_set_to_33_deg.JPG
http://www.geocities.com/axlmyk/lighthouse2/Table_set_to_33_deg.JPG


The side panels are made from 1/4" oak ply cut in 2x2" squares for the bottom, and 2x1" for the top. 2x3" pieces of plexiglass make the windows.

The top is made from 1/4" oak ply cut into triangles 4 1/4" tall with a base of 3". I made a simple jig to ensure all pieces were the same height. I drew a line on the base plywood the jig was clamped to, and sanded them till they were the same. I will be making a jig to simply cut them correctly in the future.
http://www.geocities.com/axlmyk/lighthouse2/top_pieces.JPG
http://www.geocities.com/axlmyk/lighthouse2/top_pieces.JPG

http://www.geocities.com/axlmyk/lighthouse2/Jig_to_check_length_of_roof_pieces.JPG
http://www.geocities.com/axlmyk/lighthouse2/Jig_to_check_length_of_roof_pieces.JPG

http://www.geocities.com/axlmyk/lighthouse2/Check_length.JPG
Next step was to get the top pieces ready to glue together.
I put the sander table at 12 deg and brought the edges to the angle.

http://www.geocities.com/axlmyk/lighthouse2/Table_at_12_deg.JPG

http://www.geocities.com/axlmyk/lighthouse2/Sand_the_edges_to_12_deg.JPG

Now to join the roof pieces.
Painters tape was used to tape the edges together, then I flipped it over and ran beads of glue in the seams. Brushed it in good and put it together.



http://www.geocities.com/axlmyk/lighthouse2/Top_glued_up.JPG

Now, here is a view of the test assembly. I can make a bird feeder out of it if I cut a bit from the bottom side panels. Put a cone in the bottom, and devise a way to make the roof easily removed.

http://www.geocities.com/axlmyk/lighthouse2/Preliminary_test_fit.JPG

I could also wire it up with a low voltage lamp in it. The bottom of the lighthouse is yet to come. I figure this one could be as tall as 4-5 feet.
 

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Really nice work Mike. I would use it as a outdoor lamp, but my wife would like it as a bird feeder. Post more pictures when it's all done
 

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Very clever Mike but what happened to the photographs? I still intend to make a lighthouse as per you're thread of some months ago.
 

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Hi Mike

You are getting it down..I look forward to seeing your jig ...

Nice job buddy :)

You and John C. should talk (the bird house man) he may have a jig he can share with you.

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Looking good Mike. Keep up the good work. :)
 

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Discussion Starter · #9 · (Edited)
Top is done

Well, I finally got to a point where I can say the top is done.

I first glued in the bottom panels then prime and finish painted it. Then the windows went in, and the prepainted top panels were slid into the slots. The top panels will remain loose so the windows can be replaced if ever needed.
http://www.geocities.com/axlmyk/lighthouse2/100_2585s.jpg

http://www.geocities.com/axlmyk/lighthouse2/100_2586s.jpg
http://www.geocities.com/axlmyk/lighthouse2/100_2586s.jpg

To attach the top, I cut 3/8" off the inside tops of 4 of the columns. A piece of plywood was cut to fit and screwed down. A 3" screw goes through the roof, and a finial holds it in place.


Now I'm working on the base. It will be 4' tall and 8 sided.
The side panels will be 9" on the bottom and 3 1/2" on the top.

Time to make some more sawdust.
 

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O to have you're skill, imagination and patience Mike.
 

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wow that is great! good use of a sander!!!! This thread should be showed to kids in 5th grade geometry when they say "When will I ever need to know this"...
 

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Discussion Starter · #15 · (Edited)
Getting the base together

This is a test fitting of the base section.
Instead of using a jig to cut the base pieces out, I stacked 3 pieces of 1/4"x2x4ft poplar ply together and cut them with the TS. I then used a jointer to bring the edges true and equal size. A little trimming of the top and bottom edges and they were done. I then ran the long edges on the RT with a 22.5deg. bit.

The bottom inner brace is made of 1x2 pine cut to 8 5/8" on the long side at a 22.5deg. angle. I glued and stapled them together. It stands 4ft 10 in. tall.
 

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Great job Mike! Now all the little boats on the pond will be able to find their way home. ;)
 

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Hi Mike


I like it :)

I like the details on the top, how did you make the uprights and put the small screws in place without splitting them ?

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Discussion Starter · #19 ·
bobj3 said:
I like the details on the top, how did you make the uprights and put the small screws in place without splitting them ?
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I predrilled the holes for a #4x1/2" screw. To attach the beacon house to the top plate I used 4 #6x1 1/4" screws.
 

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Discussion Starter · #20 ·
Joe Lyddon said:
Hey Mike,

That's a lot bigger than I thought it was going to be!!

Looks GOOD!

Where did you say you were going to put it? :) :D
Wait till I design my next one. A neighbor wants one 8 feet tall.

I'm thinking I'll put it in the front yard with a for sale sign on it.:sold: Unless of course the other resident of this house wants it.;)
 
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