SANTA_SLEIGH_REINDEER

The steps in which inspired this project started when Jerry and Edith attended the PLUS2005 conference. "We were amazed with all of the ideas and the technologies that were available. We had only been members of the Planet Christmas club for about 5 months before the conference. We have always been amazed at watching the animations of many designs of wireframes in the yards during Christmas. One of the classes at the conference really opened a new world of designing which can be performed with wire frames."

After PLUS2005, Jerry established many creative ideas that he wanted to incorporate into his 2005 display. He finally settled on one idea and the goal was to have it completed by Thanksgiving 2005. Unfortunately, his career took him away from starting the plans. His occupation required him to be located in the New Orleans area during the aftermath of Hurricane Katrina. He was only able to be at home on the weekends and the dream idea had to be postponed until January 2006.

Jerry began by reading additional information from the PLUS2005 education book regarding wire framing. He followed the advice of many whom had input into the book and classes. Listed here are the steps Jerry took to develop his "Santa, Sleigh, and Reindeer" project:

He searched for the correct type and size of welder that would fit his needs for the present and future projects. He located a Mig welder from Harbor Freight for about $250.00.
Searching for hot rolled steel was very difficult. All of the local supply companies were too expensive or did not carry hot rolled. Most carried the cold rolled rod. After much search, he located a metal supplier about 60 miles away. Even with the gas prices so high, it still was much cheaper to drive and purchase the quantity needed with a few extra pieces. The company required a minimum purchase of $75.00. Jerry purchased 800 feet of 1/4” rod and 200 feet of 3/8” rod. He also purchased 40 feet of ½” square tubing, to be used for channels for the gift box supports.
Jerry purchased the Rotary Bender, however, had little luck using it on many of the turns. He used a 6” bench vise for every bend needed. The curves were made by opening the vise jaws up enough to allow freedom of the rod to be bent in short intervals mixed with some good 'ol "common sense".
Jerry searched the Christmas sites on the web to locate any drawings that may have Santas, reindeers, and other related pictures. He utilized the "Paint" software in the Windows program to edit the pictures to match the needs for the design. He then printed the images on transparencies so they could be projected onto a sheet of tile board, 4’ x 8’ in size, in which he purchased from Home Depot. Jerry traced the outlines of each image onto the tile board (aka dry erase board). As he cut and bent the pieces, he laid them on the board to size up the finished sections.
Once all the pieces were bent, cut, and labeled, he began to weld them together. He laid down a ½ sheet of used plywood and laid the pieces on it in order to weld. After welding each section, he then used a hand grinder to smooth down the welded areas.
Jerry purchased 6 cans of Krylon Primer and the same amount of paint after reading that many used a good primer and paint and had very little issues with rust. He painted all areas of the frame black that are used for supports. The remaining portions were painted white, which the rope lights will be attached to.
In 2005, Jerry purchased 300 feet of 3/8 clear rope lighting. After calculating the additional items that have been added to this project, he will be purchasing an additional 150 feet from Action Lighting.
During the length of the project, Jerry has been purchasing multiple colors of "Krylon Glass Paint" from Michael's craft store each time they run a 40% off sale. The paint can be used on the rope lighting and the metal rod it is strapped to. It is easier to paint than to splice each color in a run of rope lighting.

The project has taken about 1000 hours to build. Jerry works on it a little at a time, so as not to take the fun away. The display will stretch over 35 feet across the roof. Jerry has really enjoyed building his first display and provides a tour of the project each time guests come to the house. "Ooohs and Ahhs" are required. :) Jerry will be designing a new project for the 2007 Christmas season... so stay tuned for more exciting Christmas projects to come!