Step 1.
To start with I bent wire for 3 large triangles. And welded them together at the correct angles. ie 60º between each, so when looking from above it looks like umbrella spokes.

(Tip - Weld the first triangle closed, loop the 2nd inside before closing its corner - like a chain link. Otherwise the 2nd and 3rd will be compressing the 1st when trying to assemble)

Step 2.
Once the 3 large triangles are together (looks sort of like a pyramid) I made the 6 points which will be attached down each side. The points need to be 2/3's the length of 1 side, bent in the middle. I actually made 2 of them with longer tails so they could be cross braced for some stability.

To get the small points to line up with the main triangle, I used another table against my workbench with a gap between them, which allowed 2 of the triangles to dangle below the bench. Once all 6 are done it looks something like the pic.



Step 3.
Attach the pole. I already had a square pole mounted in my tree, so I used a slightly smaller square post for my mounting pole. I cut 3 slots in the end of the pole so that the base of the 3 traingles would fit into them. Next I added 6 braces which act as the bottom point. The braces were 1/3 the length of the original triangles.
Measure in 1/3 from the tips of the bottom and this is where they will be welded. To line up the post I again used the 2nd table with the bench and looked from the top of the star. Here's the same view but on the ground.

Step 4 - Paint
Once the 6 braces are done, its time to clean up the welds and give it all a coat of paint. I found hanging the star from the post at a workable height the best way to paint it and also attach the lights.




Step 5 - Lights
Next work out spacings between globes. The lights I was using are 36V and in sections of 15 globes. 3 sections of 15 would do each star. Making it 15 globes for every 2 points (3-4-4-4 per side) Get 2 friends over to help with this bit (It goes alot faster.)

Again with the star hanging start with the end globe of the run at the TOP (actually the bottom) so the runs will finish back where you start. We used clear cable ties (zip ties) on each globe holder.

Last thing before installation - connect your controller and test.

Cheers
Dave




This Project Created By Dave Kenny
www.manningchristmas.com/au