How to make a Wooden Star Map Nightlight
We just had our first child and being a space nerd I wanted to commemorate it with a print of the night sky the day she was born. You can purchase prints like these online, but I wanted to take it a step further and make it light up! Here are the materials and tools I used to make it:
Frame Mounting Hooks
Step 1: Create the Star Map Image
I used the Inventables X-Carve to drill out all the stars. To do that I need to download the star map on the day and time my daughter was born. There are several sites online that will create prints like these for you, and I used Greater Skies. I did have to pay for the print, but unlike other companies that do the same thing, they allow you to download the PDF for around $30.
Once I had the map I then:
Imported the file into Adobe Illustrator and did an image trace (using the logo setting)
Expanded the image trace, ungrouped everything and turned the stars from white to black
Added my daughter's name, birthday, time and coordinates at the bottom.
Exported the file as a .svg
From here you could send your file to a CNC in a few different ways. Since I'm using the Inventables X-Carve, I wanted to get the file into their free software Easel . I found that my file was too large to import directly, so I first brought it into Vectric's V-Carve and then exported G-Code to then import into Easel
Step 2: Cut Out All the Stars Using a CNC
This step took a looooong time. All in all, there were a little over 2000 holes that it took the Inventables X-Carve 6 hours to drill!
I used a 1/32 bit to get the stars(holes) as small as possible. One thing I wasn't able to replicate was the varying star sizes in the original print, but the result still was great.
After the stars had been cut out, I spray painted the top white. I painted the sign before carving out all the words so that the wood color would show through the top coat of paint.
The words were then cut out in a separate CNC operation using a 60-degree V-Carve bit.
Step 3: Build the Frame
The frame was a simple 2 part construction.
After trimming the final sign to size, I first made 1x3 strips of construction pine for the walls. These were butt jointed together with wood glue and brad nails. I took all my measurements directly from the finished sign.
I finished the frame with additional 1/3 strips, this time I used a crosscut sled to create 45-degree miters. You can also make these cuts on the miter saw. The top frame was again put together with wood glue and brad nails. The brad nails served as a clamp so I could keep working as the glue dried. There is a half inch overhang on the inside of the frame, this is what the sign will attach to.
Step 4: Adding the LED Lights
I used cheap LED lights from Amazon. These DO NOT come with a power supply so make sure to purchase an adapter when you get the lights....or you will be waiting to plug it in like me ;)
The lights have an adhesive back that I wrapped them around the inside of the frame. I then used a 1/2 Forstner bit to drill a hole in the side of the frame to route the end of the LED cable through.
NOTE: If I were going to make this again I would have put the plug flush with the side of the frame to keep the wire from dangling from it when not plugged in.
Step 5: Attach and Seal the Sign to the Frame.
The sign was attached with wood glue to the inside of the frame. I was worried about light leaking through the edges so I sealed everything with caulk. This was probably overkill but seemed like a good idea, ha!
I finished the frame by sanding it down to 220 grit and then applying 1 coat of stain.
Step 6: Attached the Back
I sealed the entire frame with another sheet of 1/4 plywood. I cut this out using my crosscut sled on the table saw. The back was attached to the frame with brad nails. I didn't use glue so that I could remove it if I needed to get inside.
Hanging hardware was mounted to the back.
NOTE: If I made this again I would have made the frame so I could slide the back into it. This would allow it to be easily removable.
And that's it. This was a fun project to make and I got to try a bunch of new things. We love having a cool way to highlight the birth of our daughter!