Using a pencil drawing that was to the scale of the rough flexible wire frame I’d previously made, I created a stronger more realistic frame work from steel rod.
Using the workshops machinery I cut out and soldered the individual components of the framework.
The images show the spines pertruding from the steel plate on which the heat sink will sit. I hope these points will stop the heat sink moving.
Unfortunately when deciding to lengthen the spines upward and sit them neatly into the edges of the steel plate, I did not account for their addition to the width. This meant the steel plate became to narrow for the reflector to sit and as a result , small cuts had to be made to the reflector base.
Now that I have some sort of frame I can model the leather on it with the light in place to create the best form.
The benefits of viewing the errors early mean I can alter this frame to make a wider steel plate with whole new frame if need be. This would let the reflector sit flush to the steel plate which is important as the design should work perfectly with the Xicato products provided by the client.
I need to investigate if small wire hooks braised to the spines would help keep the leather in place rather than sit itching or gluing.
When modelling with this frame and the leather I will need to ensure the light quality remains as measured previously with the paper model.