2023 Journey - First display for JohnnyBoy

Johnnyboy

Full time elf
Joined
Jan 2, 2023
Messages
220
Location
Perth
Hi All,
About time I created a post with all that i have learnt so far and how my journey is unfolding.

In 2022 i got into the Christmas spirit buying a bunch of standard led lights and ornaments and decorated the back yard. Then in the Boxing day sales this evolved into buying more lights and ornaments. Sometime before the new-year i started googling Christmas lights and stumbled into the world of pixels. It was eye opening and i just knew it was something i wanted to do. Lots of googling and several reads of the 101 manual i decided xlights was the way to go.

I saw a previous post showing a detailed list of everything they had bought where it worked out to be around the $3000 mark for 2000 pixels. So i thought a $5000 budget would get me something quite awesome. Little did i know how that budget would grow!

The Layout
Enter my first xlights 2D layout.

Quite respectable and my final layout hasn't changed the basics to much. I did learn a lot about modelling and how to set it all up along the way. It's more complicated, yet more simple at the same time. Xlights is feature rich and figuring out how it works has been an journey, one of which i'm only just understanding.
My wife wanted all the stars/snow flakes and i was happy to accommodate. After this, we both spent quite a lot of time going through YouTube and the forum to see what layouts we liked and also to see what sequence styles we liked (purchasing sequences this year at least). The discovery of Magical Light Shows really influenced our layout and we mostly just adopted their layout which really increased the number of pixels.
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Upgrade to 3D and final 2023 layout
After reading up about the benefits of 3D, i got to work on a detailed Sketchup model and brought that into xlights. Quite the learning curve working in 3D but managed to get it sorted.
So below is how the 2023 layout is looking. Tune To sign will be moved but thats about it. I keep thinking about a matrix or two, but it might just have to wait till 2024.

This has really increased the complexity for mounting being on the roof so much, but i've done lots of research and believe i have a way forward for all times. Time will tell!
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Props and outlines
Mega Tree - 150x30 + 270star
Archs - 4 x 126pix 3ring arch
Trees - 8 x 105pix 1.27m
Canes - 7 x 99pix
Flakes - 20 x 48pix
Showstopper flake - 750pix
Spinner - 2 x 30pix
Icicles - 20m @ approx 87pix/m = 1300pix
Roof/house outline - 1 inch spacing - 57m - 2400pix
Tune to - 329pix
Total - 12,943pix

Orders placed for all of the above and now have about 90% of everything in hand for building. Only thing yet to arrive are the custom strings i've ordered.

The Cost
For better or worse i have been tracking every dollar spent and its very eye opening on how quickly things add up. The total is waaaaay above the $5000 budget i had when i started, there has been a few conversations with the wife as the totals have gone up. Thankfully she is very understanding and supportive of my hobby.

I've seen it repeated a number of times that an all in cost of $1/pixel is about right. Well so far i've ordered 13,500 pixels with a plan to use 12,943 of them. Costs to date $12,846, with an estimated $840 to go. Below is a list of items that i have ordered with the coloured items still to be ordered. There will be more things to order, but hopefully i've considered most things. I've not shown individual prices but you get the idea.

I've chased the savings as much as possible with many many aliexpress orders. Thankfully i have the time to wait for the 1-2month shipping on some items.
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Controller Boxes and How its Connected
I wanted to get everything sorted as much as possible on paper before i building too much and figuring out cable runs, PI, controller box locations and how its all connected.
Everything will be connected to a single F48V4 in the roof that has easy enough access to the roof ( i have roof access from a ladder in the garage). From there i will have 3 additional controller boxes with either 2/3 receivers in each box. Show will be running at 40ffs so i've limited the max pixels per port accordingly. Its looking like my max is 616 on a single port.

Box 1 Roof - F48V4
- 4 channels used directly off the F48 to drive the top left of the house.
- 1x600w PS
- Channels 45-48
1682047609968.png

Box 2 Roof - 2 receivers (only one in use, second for expansion at later date)
- F48 input 6
- Channel 21-24
- 2x600w PS
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Box 3 Ground - 2 receivers
- F48 input 9 & 10
- Channel 33-40
- 2x600w PS
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Box 4 Ground - 3 receivers
- F48 input 1-3
- Channel 1-12
- 3x600PS
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Building the Boxes
I've managed to put together the F48 box and one of the 2 receiver boxes. I didn't take a photo of the F48 as yet, but i'll upload one when i get the chance.
I may upgrade the timers to a wifi enabled version, but these will still do the job.
Fans/Covers - da.share
Receivers - Hanson
PS - Lightitup
Box - Digi key Bud 23026
Mounting plates - Extreme Lighting
1682049066416.png

Injection Boxes
As i want to limit the length of the PI extension cables as much as possible, i've constructed a bunch of power injection boxes that will enable a large 6mm2 cable from the PS to the PI box that i can locate right near the props. More work yes, but hopefully this simplifies connections a little, and has less cable length overall, time will tell. At this stage i haven't figured out what power connections i will be using. I have a few options and would appreciate any feedback for use on 12v
- Powercon - these seem to be limited to 20A, but i believe this is at 240v? I do like the simplicity of the connection though
- Solar power connectors - i think this is the option i'll use as they are designed for 12v. Costs do add up for these.
- EC5 connectors with heat shrink. I have a bunch of these already from my RC days, not water proof, but i could use heat shrink to make them quite water tight. Its the free option and i quite like that price! Plus they have some crazy current carrying ability.
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I've got lots of projects in the works for mounting etc and will update the post regularly when i get the change.

Comments and feedback always welcome!
 
Looking great. Can’t wait to see some video in December. (Perth might be a little far to travel to visit)
 
Massively impressed with your progress. Makes me think that I need to pull my finger out if I am going to have anything to show come Christmas time.
 
Great job so far and look forward to your continued efforts. While looking over things, and I did not read everything in detail, a few questions came to find.

1. what is the spacing of your megatree, just curious. I saw the note for the eaves and just wondered.
2. what sort of backup hard do you have if the f48 or one of the receivers dies during show season?

Dean
 
Great job so far and look forward to your continued efforts. While looking over things, and I did not read everything in detail, a few questions came to find.

1. what is the spacing of your megatree, just curious. I saw the note for the eaves and just wondered.
2. what sort of backup hard do you have if the f48 or one of the receivers dies during show season?

Dean
Spacing on the megatree is 1inch. I'm about 1m from the footpath so it was really needed to get the definition.

Backup....... I have a few spare receivers but only the one F48. Not much to be done if the controller goes out.
 
At this stage i haven't figured out what power connections i will be using. I have a few options and would appreciate any feedback for use on 12v
- Powercon - these seem to be limited to 20A, but i believe this is at 240v? I do like the simplicity of the connection though
20A is 20A, regardless of voltage.
However, PowerCon is suited towards mains 240v, so I wouldn't use them on 12v because it is not standard use for them.

Great write up! 12k pixels is brave for a first year.
It is good to see you have a decent grasp on this, there is many people who start this hobby and have more money than safety/knowledge to wire it up!
 
20A is 20A, regardless of voltage.
However, PowerCon is suited towards mains 240v, so I wouldn't use them on 12v because it is not standard use for them.

Great write up! 12k pixels is brave for a first year.
It is good to see you have a decent grasp on this, there is many people who start this hobby and have more money than safety/knowledge to wire it up!
Very true.
I've decided to go for the solar power connectors as they are intended for low voltage and will do the job nicely. Ordered a few days ago so will be about 4weeks to arrive.

Thanks for the compliment. Its taken a lot of reading and research to figure it out. I'm definitely a beginner but feel like i have enough a gasp to not hurt myself/others and get a display to work.
 
Master control box - F48
Here is the F48 control box, being the learning experience that it is, i finished the box without putting in the Beaglebone or sound card inside......... Not to worry, another order to AliExpress for a 5V power supply and i'll be good to go in a few weeks. I think i just got excited to get it working.

I originally planned on making my own network cables and after making 5 or so, they were just so chunky that it wasn't going to all fit. I ordered a bunch of these small patch cables and they are fantastic! super flexible and very very thin.

This box has/will have the following
- F48V4
- 1x600w PS
- 12x RJ45 outlets
- Channels 45-48
- Timer will be updated to a Shelly 1PM Plus at some stage
- Beaglebone
- Soundcard & output to FM Transmitter
- 12v wires to the back corner will be to a power injection box shown above.

I found a error with the F48 screen that only half the pixels are showing/working. I've reached out the PixelController and they will be sending me a replacement one once they are in stock. Still usable, just hard to read.

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Icicles
The icicles have been really fun to put together and even more fun to run a sequence through them.

Im using the Extreme Lighting Display HDPC/Plastic type icicles that are really easy to work with. They are super thin meaning no tools are needed to push the pixels without being too ruff on your thumb, plus they cut with standard scissors. Each section is 1.8m/156pixels so ive cut them to make 200pixels per length of conduit for ease of handling/mounting. I think it was the right move as even at 200pixels they are quite awkward to move around. All mounted to 25mm electrical conduit with way more zip-ties that it looks. I recently placed an order for 1000 more zip-ties....hopefully enough for the season! Also plan on doing some spot painting of the zip ties to make the black less visible, not sure when that will happen yet.

I've now built 3 of the 4 icicle sections with the 4th to be finished in the next week or so when i have time.

Sizes
1 x 1.8m (one full length)
1 x 4.6m
1 x 6.75m
1 x 6.4m still to be built
1682567953933.png

Quality control manager doing the rounds
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Last edited:
The current bane of my existence, holes holes and more holes!

On the to do list
2456 12mm holes
2456 18mm holes on the back

All at 1inch spacing. Do i need it? no, but it should look cool!

Getting there but boy it takes some time. I'm onto a good system and can typically drill about 400holes/hr provided the marking has been completed. Markup up the hole locations takes about a hour for 8 lengths of pipe. I was originally doing 2 lengths at a time, but the time required for 2 vs 8 is very similar and using a set square lines up everything nicely.

I'm using a stepped drill bit as i didn't like how a forstner bit worked. Really enjoyed using the stepped bits. Very smooth and fast.

I made up a little jig to keep the conduit from rolling around. Two bits of wood with a 2cm gap in the middle....high tech i know!
1682568393687.png

One Length done....
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very nice build.. but like to see you use brown and blue on the 240v side of psu.
I did on my second case build with the smart receivers. F48 was first build and I agree the 240v side really should reflect the cable colours.
As I’m replacing the timer it’s an easy thing to change when I do that.
 
Some solid work there. Good effort!

I'm assuming that you intend to do some more power work on the icicles? You're getting some pretty decent voltage drop and yellow/red LEDs at the end of the string.


Icicles
The icicles have been really fun to put together and even more fun to run a sequence through them.

Im using the Extreme Lighting Display HDPC/Plastic type icicles that are really easy to work with. They are super thin meaning no tools are needed to push the pixels without being too ruff on your thumb, plus they cut with standard scissors. Each section is 1.8m/156pixels so ive cut them to make 200pixels per length of conduit for ease of handling/mounting. I think it was the right move as even at 200pixels they are quite awkward to move around. All mounted to 25mm electrical conduit with way more zip-ties that it looks. I recently placed an order for 1000 more zip-ties....hopefully enough for the season! Also plan on doing some spot painting of the zip ties to make the black less visible, not sure when that will happen yet.

I've now built 3 of the 4 icicle sections with the 4th to be finished in the next week or so when i have time.



Quality control manager doing the rounds
View attachment 22840
 
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