Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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I have had a desire to build and observatory but can’t seem to convince the CFO that we need a roll-off observatory in the center of the back yard where the most sky can be had. I am plagued by several inconveniently placed neighborhood lights and almost always a breeze. After seeing some nice homemade and professional built portable light blocking and wind blocking screens an idea was hatched to solve my problems.
This thread is about equipment that is an observatory that aids in light pollution and is a DIY project. Figuring what forum to post in was hard. I finally picked this one since Carol’s Picks in this forum has other projects like this in it. Carol rocks!
This is my second go at light and wind blocking. I have used a self modified EZ-UP for a few years. Do a search in the Observatories forum for “light eliminating module” if that interests you. However, newer bigger scopes won’t fit in my old shelter and I miss the still, dark, air across my eyes. I decided to build my own to save significant money and be able to customize the size to my needs. It was here on Cloudy Nights I received ideas and input that lead to the creation of the “Black Hole” and I thank you all. I wanted to post this thread to help others learn from my mistakes and hopefully benefit from any ideas.
Here is my material list:
- 32 PVC schedule 40 pipes 1”x10’ @ $2.23 each
- 32 PVC elbows @ $ .48 each
- 52 PVC “Ts” @ $ .59 each
- 10 2” SS hose clamps @ $9.70
- 20 yards of 56 inch wide 16 oz. Duvetyne “Commando Cloth” @ $2.99/yard
- 8 boxes 1”x6’ Black Sticky Back/Iron-on Velcro tape @ $6.59 each
- 8 spring clamps, 9” @ $12.99
- 1 pkg. of 8 Taut-Tie rope holders, small @ $7.00
- 100 ft. 3/16 Nylon Rope @ $7.87
- 8 plastic tent stakes @ $ .50 each
After shipping charges the total project cost came to $320.80 with each panel costing $40.10. That money (and some sweat equity) got me an 8 panel, 11’ diameter, 427” circumference, 88” tall, portable, open sky observatory.
Commercially I could only find one product that was similar made by Observatech. Their “Softberm Portable Observatory System” of 12 panels, 8’ diameter, 294” circumference, and 84” tall was priced online at $795 before shipping. So for less than half I got three feet more space and it’s tall enough for my needs.
Here is how I made it.
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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I found Duvetyne a.k.a. “Commando Cloth” to be the most recommended and used fabric for the panels. The film and theater industries use it as a light block and drapes and refer to it as poor man’s velvet. A wholesaler out of New Jersey, Magna Fabrics, shipped me a bolt of it for $2.99 per yard. Don’t be alarmed by shipping fees. This stuff is heavy in the amounts I ordered. I found it other places as high as $12.99 per yard. I got more than I needed in case I wanted to expand to 10 or 12 panels. The fabric arrived via UPS without incident. At 16 oz. this 100% cotton fabric it is about as heavy as broken in denim/jean material. It has a smooth, denim like side and a soft fuzzy side. The edges seem unfinished; however there is a selvage stitch along each side that keeps it from unraveling. It came 56” wide so that dictated the width of each panel. Duvetyne blocks the light completely. This is deluxe stuff perfect for this application.
 
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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I rolled it out and cut it to 90” lengths allowing for hemming the bottom and top. A square and white fabric marker helped make the cuts straight. I used a guide to get a straight ½ inch hem when pinning. Pinning the heavy fabric only bent a few pins the whole project. The decision was made to leave the side edges naked and not hemmed. This came after close inspection and picking at the edge to try to get it to fray. I couldn’t easily so after consulting my wife we decided it was okay to leave alone even though it looks a little ragged. It also diminished labor a lot.
 
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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Over to the ironing board the panels went to have the hems pressed, doubled over, re-pinned and re-pressed. Then they went downstairs to my wife who so lovingly helped with running the sewing machine. She used an old Singer, regular black thread, and regular needles. They burned right through the double doubled heavy fabric without a problem. Thanks sweetheart! After hemming the fabric panels finished at 88”.
 
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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Fastening the fabric to the frames was the next engineering hurdle. I have seen screws and washers used with other systems with some success. Moderate tearing at screws had been reported here and there. I also had seen sewn in pockets.
I decided to fasten the fabric to the frame via Velcro. I found an iron-on loop/sticky back hook product by Velcro that fit my needs. The iron on at first made me shy away worrying about strength. However, after reading up on it I decided to give it a try. This stuff is strong. The manufacturer even says that the bond gets stronger with washing. I looked online but found it cheapest at Wal-Mart boxed two ways as you can see. It is the same stuff in either packaging. It comes in a box with both the sticky hook and iron-on loop 1”x6’ tapes. I cut the 6’ strip into two inch strips for some adjustability and fudge factor. It took just a little less than one box per frame.
This one design feature changed everything. The fabric panels can go on and off for transportation or washing now. Velcro fastening also made the panel almost wind proof without fear of a gust ripping through a screw/washer. I think the added expense by going with Velcro will be offset with the added strength and convenience easily.
 
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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I pre-assembled one frame (you will soon see how that went) and used it as a template to mark the fabric panels with that white fabric marker I used to mark the hem cuts. The marking helped put the iron-on Velcro loop pieces in exactly the right place. There is a plastic backing that peels off and reveals a sticky side that holds the loop in place before ironing. It isn’t real strong adhesive but does well enough to keep it where I wanted it. I just lined them up and pressed them down. It took 33, two inch tabs per panel. There is no doubt in my mind that this is way more than necessary but dad always built things to last the apocalypse so I guess I should too.
I put the Velcro loop tabs on the non-fuzzy side so the soft, quiet, velvety side of the fabric was inside of the observatory. The instructions advised an iron to the opposite (fuzzy) side, using a cover cloth, highest temperature setting, and steam for the ironing. Exceeding the recommended 60 seconds to 90 seconds over each loop patch made the adhesive really penetrate the cotton I found. I think the thickness was the issue there. I would suspect the fabric to fail before this bond. Well done Velcro.
 
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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The tubing was cut to correct lengths and numbers. A compound chop saw with a standard blade made short, square, clean work of each cut. I pre-fit each piece and cut them down to perfect length on a master frame before going into production. Clamps and a 2x4 made a nice stop/jig for each length to ensure uniformity. Four 10’ tubes were used for each frame with a little scrap left over. I needed the following for 8 panels:
48 cut to 24”
40 cut to 54”
16 cut to 9”
2 cut to 32” (doorway arch)
After cutting the tube I marked each piece with a sharpie marker to uniformly place the sticky back Velcro hook tabs. These were cut at the same time as the iron-on tabs were. Goof-Off was necessary to clean the scissors since they kept getting gummed up horribly. The sticky is very sticky. I had to tear off a couple to replace them and it is very tough. Well done Velcro again. It also has an easy to peel of backing and then just presses on.
 
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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After what seemed like a million sticky back tabs and a million iron-on tabs it was time for some assembly. Here you can see a pile of tubes ready for assembly. The exploded view shows you how the frames fit together. There is symmetry to the pattern of tabs so each tube can be turned both ways and still match up to the fabric tabs. I made sure the tabs were on the tube’s printed side so the fabric would cover this and only clean white would show around the outside of the enclosure. When fitting together I also made sure each piece was pressed in as far as it could be for strength.
 
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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Hose clamps improvised as hinges thus joining two panel frames together. Two clamps were used for the hinges on each set of panels. These are very durable and I am certain will hold up to the most hostile winds. The hinging action is easy and smooth.
  
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
|
Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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The fabric sticks almost too well to the frame. I think these will hold up to any wind and would only fail at near hurricane force. I set the frame upright, laid the fabric on the floor in front of it, and lined up the bottom row of tabs first getting the height just right. After centering the panel and getting the first row just right I moved up a row starting at the center, pulling out slack, pressing it to its tab, and working out. I repeated this series for all five cross bars. The side tabs were then tightened and adhered.
Once they all were done it was time for set up. I take them out one hinged pair at a time and set them up at an acute angle kind of where they need to go. After two are standing up I clamp them together at the non-hinge joint.
 
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
|
Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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I had these 9” spring clamps in the shop so am using these for now. However, they get duty in the wood shop so are going back. I ordered a set of 10, 9” spring clamps on e-Bay for $12.99. They are in the mail at the time of this posting.
These clamps are the perfect size and even have a cut out that squeezes the tubing perfectly and very securely. A clamp high and low at each joint does the trick.
 
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
|
Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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Now it is just a matter of hauling paired sets of two panels at a time, standing them up, opening them a bit, clamping high and low, and repeating. This picture shows how they react to a high wind while setting up before guy lines. You can see the light on the left panel and how the Velcro is holding the fabric while it quietly billows/fills up in the wind. The wind got as high as 20 mph while setting up and didn’t cause any tipping. I would sail a ship with these.
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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Tie downs and stakes finish out the system. I used a product called Taut Tie, some 3/16 nylon rope and some plastic stakes I found at the local REI. I cut the rope into 10’ lengths and tied on the Taut Ties as directed in their instruction. The other end of the rope guy lines got a loop tied like this.
  
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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When the system of panels is aligned and in just the right place I thread the guy line loop through each joint and then thread the other end of the guy line through it. After cinching this up the line loops around the stake I just pounded in to the lawn. I pull it tight and the Taut Tie does the rest. There are depressions in the plastic to show you how to thread the rope through it. You can tighten these easily and then when released they hold very well.
  
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
|
Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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This picture shows how I set up the entryway. I use a labyrinth like in dark rooms and old school x-ray processing rooms. I left two of the panel fabric sheets off so you can see the framing detail and the inside of the observatory in the pictures.
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
|
Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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In this close up you can see where the two 30 inch pieces, 4 elbows, and 4 pieces of scrap fit. They make matching archways adding support and strength. I overlap the two doorway panels about half way then press in the arches to “Ts” above. The hallway it makes is about 22 inches wide and I move in a little sideways but not awkwardly. Again, two panel frames are naked here for ease of viewing. The labyrinth entrance is very effective at blocking light across the door without flaps or doors to mess with, light gaps, or a threshold to trip on. Alternately I could set it up differently by swinging it all open across the 30 inches arch in a more round set up. If there was a dark direction for the door gap this would work best. Doing this also opens up the observatory system to a whopping 486” circumference and over 13’ diameter. I would crave this space if I had both scopes set up and/or a few folks along for the night. Having the door open would also be more inviting to visitors at a star stare or other outreach site.
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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You may have noticed the moon chart. I needed to put something on the walls so I wouldn’t keep walking into them. It is so dark inside it has been dubbed “The Black Hole”. I used some extra Velcro to secure the poster and it would also survive the same hurricane the rest of the system would. It came laminated. I have a couple others on their way in the mail. Observatory bling!
I am in the one picture to add size perspective. I am 6’5”, 235 lbs. and that is an XT10i in the background on a platform/pier. I love the 88” height. I never stand up to have a porch light hit me in the eye, it doesn’t obstruct my views beyond what the house and trees already do, and it is taller than both of my scopes. Having it taller than the scopes has caused a major increase in contrast. As much as flocking the tubes would. In fact, I am not going to flock now because of it. There just isn’t any scattered light in the “Black hole”.
The last picture gives some idea how it sits in the back yard.
  
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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So here it is without the two door panels. The Black Hole is a dream to set up, use, and take down adding 10 minutes to the front and back of any viewing session. Well worth not having a breeze across your eye making it water during that moon transit across Saturn. It will last longer than my eyes I am sure. I went to Home Depot today to get tubing for two more panels. I want to make it 540” in circumference, over 14’ wide, for those two scope nights.
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
|
Project Galileo
sage
Reged: 11/14/07
Posts: 405
Loc: Douglas County, Colorado
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North, East, South and West views from inside.
   
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Orion XT10i
Meade LXD55 LXD75 AR-6
TeleVue Binoviewers with Seibert 1x/1.3x/1.7x OCA
Minolta 10x50 Binoculars
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Arbacia
professor emeritus
Reged: 04/18/07
Posts: 695
Loc: Madrid, Spain
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Impresive, thanks for sharing in such a detail
Patricio
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LightBridge 12", 70´s C8, C11. CGE. ETX125
Set of Takahashi LE EPs; Ethos; DMK 31AF03.AS
CN image gallery
http://www.astrohenares.org
http://www.asociacionhubble.org
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