CH Disassembly/Assembly Line - en Masse

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Re: CH Disassembly/Assembly Line - en Masse

Postby khardy on Mon Aug 26, 2013 8:55 am

Hiya Folks,

Been cool out the last couple of mornings and have started doing a little work towards completing the CH Horizontal back to back set up.

Earlier in the summer before the junk lot closed for the summer, we picked up a ten foot post for our set up.
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Due to the way the post tappers going up, we had to make a few modifications so the clamps on the electrical box for the lights will hold.
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We acquired some 4 inch ID schedule 40 aluminum pipe then cut down to six inch lengths.
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Had to grind the collar near the top of the post down a little so our new collars for the clamps could slide over. Once in place, drilled, tapped and bolted each piece securely to the post. Since we do not have any welding equipment here at the house, filled in the gaps with JB Weld steel stick and feathered smooth.
Image

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Before painting, will sand blast areas of the base that could not be cleaned with a wire wheel.

We have been leaning towards painting this post Aluminum Silver instead of the Forrest Green like all our other posts. The two CH Horizontal lights are already painted Forrest Green. This post was originally a satin black.

Any thoughts or suggestions on the color paint for the post? Without buying any more paint, we have Forrest Green, Gloss Black, Satin Black, Fire House Red, White, Aluminum Silver, Yellow and Purple.

Cheers!





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Re: CH Disassembly/Assembly Line - en Masse

Postby Troy on Mon Aug 26, 2013 10:05 am

Satin black would be my conventional choice but a bright yellow would brighten things up out back.
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Re: CH Disassembly/Assembly Line - en Masse

Postby khardy on Wed Aug 28, 2013 9:55 am

Troy wrote:Satin black would be my conventional choice but a bright yellow would brighten things up out back.


We thought about the yellow, but think that would be a little too bright. Post would definitely be very visible. Sprayed some aluminum silver paint on the post this morning to see what it looks like. Let it sit all day before we decide if we like it of not. If not, we will move onto another color. Old photos we have seen of the CH flag mount lights around Houston were on gray/silver colored posts which were more than likely aluminum.
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Another requirement of this set up was taking apart the conduit and pipe tees.
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Have redrilled and threaded the set screws. Blasted the parts late yesterday and have soaking in phosphoric acid. Hope to primer paint these tomorrow.

Cheers!


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Re: CH Disassembly/Assembly Line - en Masse

Postby Crunge98 on Wed Aug 28, 2013 10:19 am

Coming along great Keith! :drool:

  wish I was painting signal stuff but I have to paint a bumper and a fender for a couple of customêrs  
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Re: CH Disassembly/Assembly Line - en Masse

Postby Old-Timer on Wed Aug 28, 2013 10:44 am

Like the silver Keith! :thumbsup:
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Re: CH Disassembly/Assembly Line - en Masse

Postby khardy on Sat Aug 31, 2013 8:44 am

Hiya Folks,

Sondra and I like the aluminum silver paint on the post. Shows a lot of the flaws in the casting which gives the post character. Believe it will add to the new/old look when this setup is complete.

Finished blasting, soaking in phosphoric acid and priming the conduit tees that will be used to hang the slave light. We have enough of these for at least two setups.
Image

Image

Since we do not know where this light and post are going to go in the yard, have decided to pour a 30 inch square by 5 inch thick cement slab with four anchor bolts. This will weigh about 300lbs. but will be heavy enough for this CH horizontal set up to not fall over and can be moved if needed. Not sure how much the post weighs since our shipping scale needs adjustment, but suspect it is about 150 lbs. or so. The two lights I estimate will be around 45lbs. or less. Estimated weigh of this unit will be around 500lbs.

Will insert conduit from the side through to the middle of the slab for the wire run. Near the center of the slab a pipe will be inserted so a smaller pipe or rod can be slipped through and hammered into the ground about three feet to give more stability since the setup will be top heavy to one side.

Any thoughts on how we can do this better?

Cheers!




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Re: CH Disassembly/Assembly Line - en Masse

Postby vaughnsimon on Sat Aug 31, 2013 9:13 am

khardy wrote:Any thoughts on how we can do this better?


You seem to have thought of everything!

I assume that you will use a PVC electrical sweep 90 for the conduit...right?

I like your idea of a "tap root" for your slab. I did that once for a ham radio tower base, but my "tap root" was permanently poured into the concrete. Making your "tap root" removable is really thinking ahead!

In this sandy Florida soil, I might figure out some way to use a screw anchor rather than that driven rod. It would make removal a cinch.
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Re: CH Disassembly/Assembly Line - en Masse

Postby khardy on Sat Aug 31, 2013 9:41 am


Hi Vaughn,

We plan to use 1-1/4 inch 90 pvc conduit for the wire run. Kind of like we did for the permanent setup on the CH 4-way we did.
Image

Biggest difference for the 90 will be in a slab and not in the ground. I used a "Tap Root" as you call it for anchoring Sondra's bases for her two playground animals recently. She still has two more of these to finish. Figure this system will help stabilize the monster we are putting together. Since this will be somewhat "portable," have not decided how we will run power to the light. May put a three prong plug on the end of a very short cable at the cement base in which to run an extension cord to when we wish to light this up.

With this project, ideas on how or what to do next have been steadily changing which adds to the challenge. In the end, If this comes about as I imagine, I think this will be an awesome setup!

Cheers!


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Re: CH Disassembly/Assembly Line - en Masse

Postby dkendr on Sat Aug 31, 2013 10:19 am

I know you want to keep your post semi-movable, but is your area subject to tornadoes or other strong winds? We've had a couple of bad tornado epics through here. Those things snap solid telephone poles off the ground like they're nothing and would turn that metal pole into a javelin if the worst happened.

And just to play devil's advocate, seeing as you've done a lot of homework here, is this covered by your homeowner liability insurance? It might come under "outdoor lighting display" for most policies, but then again, "traffic control device" probably wouldn't. If you haven't already you might want to check with your agent and drop the extra bucks on a policy extension if it doesn't.
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Re: CH Disassembly/Assembly Line - en Masse

Postby khardy on Sat Aug 31, 2013 10:51 am

Seems we do not have many tornados. The once in a great while hurricane yes. If the hurricane is big and bad enough, the traffic light poles and other items in the yard will not be a concern at the time. Leaving the area for self preservation will. As to our home owner's insurance, it covers our out buildings. Not so worried about the yard ornaments. Besides, our stuff is reasonably secured.

Cheers!
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