How to make ceiling star lights - Step by step guide

How to make a Star Ceiling - Step by step guide
Whether this is your first attempt to install a DIY Ceiling Stars Fiber Optic, or you`ve already done this before, our step-by-step guide combined with our star lighting kit is all that you need to make your project a success.

Follow these exact instructions on how to make a star ceiling, and your new home theatre, bedroom, or hobby project will be a success!

Step 1: Check your items

Once you receive your light engine and Pmma Fiber, make sure you test the fibre optic star ceiling kit to ensure it works as expected. If you identify any damage to the product, do not install or test it out before consulting with us first. Please note that the remote controller comes without a battery.

Step 2: Prepare the ceiling space

If you are using large or multiple boards as your star ceiling panel, then make sure you reinforce them with timber (or other suitable materials) on the edges and in the middle. We recommend that you securely place the board on work-stands. This is so that you can easily work on the back of the panel while being able to pull the fibres through from the bottom (visible) side.

If you do not have the right access to ceiling space, then you can create a frame that is big enough to house the panel. It will need to be deep enough to house the light engine comfortably. If you do this, then you will need to fit the fibre optic tails into the board will take place before securing the board to the frame.

Step 3: Prepare the visible side of your board

You can either paint your board or use fabric to cover it. Neither option is better than the other; it`s down to your own personal preference.

If using paint, then make sure you apply at least two or three layers to ensure a smooth finish.

If using fabric, firstly, spray the adhesive over the visible side of the board and attach the fabric. Work out any bubbles or creases with your hands or a roller, then secure them on the backside of the board with more adhesive spray. If you`re covering the board with black fabric, then you`ll need to ensure you are working off the ground or in a clean workspace when attaching the fabric to the board. Otherwise, you will end up getting dust and sawdust on part of the fabric; and this is time-consuming to remove.

Step 4: Mark your star points

Calculate how many star points you will have per square meter on your board and how many of each diameter (if you have a mixed diameter kit). We usually recommend 50 - 100 fibres per square meter so you should choose your star ceiling kit accordingly.

Also, consider the location of your light engine, both in relation to the furthest star points and the number of fibres per length you have in your bundle (If your fibre bundle consists of fibres with various lengths). The light engine should be placed in a dry, well-ventilated, accessible location.

Using three different colour marker pens, draw circles or crosses on the backside of the board to help you plot out where you will drill the holes for the star points to be. The number of marks you make should correspond to the number of tails in your fibre optic bundle. The three colours represent the three different diameter fibres in your mixed diameter bundle (0.75 mm, 1 mm, and 1.5 mm).

If you are looking to achieve a [night sky" effect, make the marks random but spread across the whole surface of the board. Some areas can be denser than others, just like the natural stars at night in the sky. Alternatively, draw a pattern or replicate constellations of your choice. Remember to draw the mirror image of what you want to see from below.

Step 5: Drill the holes

Using the 1.5mm drill bit, you need to drill through your pre-plotted largest star points from the backside through to the visible side of the board. Do the same for the 1mm, and then the 0.75mm fibres.

Please note that we only provide 1mm and 1.5mm drill bits; this is because the 1mm drill bits are suitable for both the 0.75mm and the 1mm diameter fibres. We recommend using a drill chuck extension to hold the smaller drill bits in place. Alternatively, you can use a combination of electrical and aluminium tape around the base of the drill bit to hold it in place.

These drill bits are fragile, so be careful while using them.

Step 6: Identify the optical fibre bundle's starting point
Once you are happy with the placement of the holes, you need to decide where the light engine will be placed above the ceiling and then mark where it will go on the board. Place the fibre optic bundle from your kit on that mark on the board.

When you decide on the light engine`s location, consider the following factors:

The light engines should always be placed in a dry location to avoid short circuits and prolong their lifetime.

It should also be accessible in the future in case of technical issues or if you should wish to change the light engine.

The distance of the light engine`s connector ports to the furthest star points on the board.

The electrical connection for the light engine.

Step 7: Insert the fibre optic tails in the drilled holes

Starting with the shortest fibres first, take out the largest diameter first and thread them through the largest holes drilled nearest to the light engine mark made earlier. Pull them through from the underside, or if access is a problem, thread them through as far as they can go, so the cables are fairly neat.

When pulling through the fibres, ensure they are not too tense and that they do not have sharp bends or breaks as this would reduce the light intensity at the fibres` endpoints. Continue this process with the 1mm and 0.75mm fibres, and then move on to the next length fibres and repeat until all the fibres have been thread through the pre-drawn holes.

Step 8: Secure the fibres
Using the black silicone or epoxy glue, secure the fibres by putting a dot on each of the hole points and leave it to dry. This will stop the fibre optics from falling back through the holes when you secure it to the ceiling. Again, ensure the fibres are not too tense and that they do not have sharp bends or breaks.

Step 9: Tidy up time!
We`re almost done! However, these final stages are essential if you want to make sure everything looks exactly how it should. With all the time and effort that you`ve invested learning how to make a star ceiling, it`s important you do a thorough job on the tidy-up aspects.

The back of the board
Once the glue has dried, neaten up any unruly fibre cables and tape down using the black cloth tape. This step just helps flatten down some of the cables even more and stops them from getting tangled. Make sure the fibres don`t break during this process.

The visible side of the board
If you have easy access to the visible side of the board, cut the fibres to a more manageable length. For example, 10-15cm of each wire hanging through.

Step 10: Secure the board

This step depends greatly on your individual scenario, whether you`re using an instalation frame or a recess on your ceiling and whether you have access to the ceiling area from above. You will have to make sure that the light engine is connected to the optical fibre bundle`s connector port when the board is lifted and secured into its final position.

Depending on the size of the board, you might need 2-4 people to help you. Plasterboard props are a great help to hold the board in place whilst you secure the panel to the frame or joists.

Step 11: Cover the screws
You can cover the screws with black felt self-adhesive dots as they will not be noticeable amongst the black fabric. If you`ve painted the board to a specific colour, paint the dots with the same colour prior to applying them over the screws. This may seem like a minor point, but where the aesthetics are concerned, it will make a huge difference and should not be overlooked.

Step 12: Cut the fibres

Using wire cutters or nail clippers, cut the remaining length of the wires down to your desired length. If your panel is covered with fabric, then make sure you do not cut them completely flush, as the fabric can cover the end of the fibres. Leaving the fibres a little bit longer creates a halo effect around each fibre, and it looks really good. Test the effect as you cut shorter and stop at your desired length. You can get a more interesting night sky effect by cutting the fibres at a variety of angles.

If you plan to paint your ceiling or board after the panel is fitted, leave 5-10cm of fibre hanging out until you finish painting. Then, you can cut them short, as the light is only emitted at the end of the fibres.

Step 13: Finish - Turn on the lights

Your panel is now ready, and you can enjoy the beautiful night sky that you have lovingly created yourself. You can scroll through the light engine`s programmes with the remote controller and set the panel to your desired mood. If the light engine you`ve purchased is Bluetooth app-enabled, don`t forget to set that one up too.