This afternoon I popped over to The Asia House and helped the carpenters build the star ceiling. I brought an LCD projector, hooked it up to my laptop, and projected the image I had prepared earlier onto the ceiling panel, which we had temporarily leaned against a far wall. We then drew with a pencil in every star and planet onto the ceiling, marking down which ones were large and small, and which ones might look good in blue versus white.
Next, we drilled holes for every star. It turned out that a 1mm drill bit was just right for both the smaller 0.75mm optical fiber and the larger 1mm fiber. I had originally planned to use multiple fibers for the larger stars, but I realized quickly that due to the limited size of the LED controller, we would not be able to fit in all the stars. So we’re going with only a single fiber per star, and we’ll use the slightly larger fiber for the larger stars. Considering the low height of the ceiling (since the floor is raised at the seating area), smaller stars will probably also look a lot more realistic.
After drilling the holes, we mounted the LED controller to the frame at the rear, at a location near the center. We then proceeded to insert the optical fibers, one per hole, and routing them to the controller with a little slack to spare. We used a staple gun to keep the fibers close to the frame, although we had to be careful not to let the staples press down on the fibers or they would break. A dab of glue holds each fiber in place in its hole.
The guy in the store where I bought the LED controller said that hot melt glue works best for mounting the fibers, since it dries quickly. However, we couldn’t get it to work as the fibers kept melting under the heat. Instead we used good old Elmer’s glue, which unfortunately needed a long time to dry so it did get a little messy.
At the LED controller, we bunched up as many optical fibers as would fit in one of the five LED tubes, wrapped each bundle tightly in scotch tape, and inserted it into its tube. Again it got a little messy; with fibers sticking around everywhere it was hard to get them bunched up evenly. Due to the number of fibers I wanted to squeeze in, we removed the cable entry ring and replaced it with some masking tape instead.
On the front side, we cut the optical fibers off with a cutter. We left about an inch of each fiber protruding from the ceiling.
Next, the guys will be covering the ceiling with a couple of coats of a matte black paint, painting right over the fibers. Once the paint has dried, they will cut each fiber off close to the ceiling, giving us a good, clean dot of light emanating at each star location.