The 2009 Belardo Fireworks Project
Using Coroplast Material
New for 2009
We were thinking about a new project that would be extra-special for 2009, and came up with the idea of building a pair of Fireworks panels for the garage door
to highlight the names of our two boys Brandon and Stephen. After all, the display is dedicated to them. So what better way to pay tribute? But how would we do it? Coroplast, of course!
How many lights would it take, and what sort of design would we use? The investigation began...This project turned out to be a lot of work, but worth it in the end...
First, we did some searching around for samples to use for the design of the panel. We found several different pieces of clip art, and several photos of fireworks.
Of course, right away, I'm thinking that it could get really complicated to try and duplicate all the various lights and firework action that goes on in a typical show. So somehow we have to
translate the way the fireworks ignite and explode into motion that the LED lights can duplicate. It turns out to be the most difficult part of the design...Back to more idea gathering.
Shooters and Explosions
We like this photo with the shooters from ground level and then the fireworks explosions...But is this even possible to duplicate in a 40" square panel?
More investigation, sketches, and design ideas...Is this just too much work?
The Grand Finale
Here's another sample we like, great fireworks action and lots of different colors or lights along with plenty of explosions. Then I start thinking, don't forget, we need to
build two of these! Lots of work, to be sure, but just think how great it could turn out if done well!
Fireworks Studies
So once we start looking at photos and drawings of fireworks, then I start to pay attention to the shapes of the various firework explosions and how they
interact with each other. Some patterns start to develop and some ideas start to come...The design is in progress!
The Shape
So here's a typical up-close example of what a fireworks explosion looks like (the bottom one). Let's work that shape into our design and see what that
looks like on a larger scale.
The Tracers
This is a good sample photo of what good fireworks "tracers" look like. Let's incorporate those into the design as well to help the overall look and feel of
the fireworks panels. More design and ideas take place...
Projection, Tracing, and Drawing
After studying all the different photos and artwork, it's time to start projecting typical photos and other design elements on the garage door so we can
begin the process of drawing up a pattern to use for the fabrication of the panels. I start by taking a large piece of butcher paper and tape it up on the garage door wall and we start tracing some
patterns on it. After much erasure, re-draw, re-design, the shapes start to take place. We decide on three separate zones of fireworks. Each zone will be independently controlled and contain a
tracer (vertical line that goes up to where the fireworks explode), a center light for triggering the explosion, the first explosion, different colored tips for the first explosion, and then 2nd, 3rd,
and 4th explosions that are lower than the first. The order of firing will be just as described above. Zones 1 and 2 will be duplicated and controlled together, while Zone 3 will be stand-alone.
So, in the end, the channels for animating will look like this:
1 - Tracer
2 - Center of explosion (C7 bulb)
3 - Explosion #1
4 - Different colored tips for Explosion #1
5 - Explosion #2
6 - Explosion #3
7 - Rxplosion #4
These channels will also be duplicated for Zones 2 and 3, so there will be a total of 21 LOR channels required to control the Fireworks. In addition, each of the channels will use different colored
LED lights from all the adjacent channels. This process to draw, design, and iterate the package took 1 month of spare time. The design is very dense with lights and I knew that it would be
difficult to build. The holes are very close together, and the various colored light strings are also close together, with some overlap in the space. It's getting harder! Having a drawing helped, though!
Over 2,000 Lights In Both Panels
Similiar to other Coroplast projects, a scratch awl is used to punch a hole for each of the LED lights. So once the design and layout was complete, then the job
of actually punching the paper and Coroplast for the lights begins. Some correction work is done on the fly as issues arise, but overall the project goes well for punching and is finished within a few
days. Of course, a second panel is also punched. The setup time for the display is getting closer, so it's time to start getting the lights inserted into the panels. Other work seems to get in the way, so
we're delayed with this project. Can we make it?
Explosions Are Numbered And Labeled
Here's a closeup view of what the panels are going to look like. There is going to be a lot of lights!!! This part isn't as much fun, as it takes hours to
stuff the lights into the panels. It's one day before Thanksgiving 2009. The panels have to be loaded with lights and completed in less than 3 days. Other setup items have gotten in the
way, but it's now down to the wire. Time to get serious!
Gentlemen, Start Your Engines!
It's time to start wiring the panels. There's less than 3 days until the display is supposed to be lit up and the panels aren't done yet. In fact, we're just getting
started with the stuffing of the lights! My dad and a friend helped, and we made great progress. It is still tedious work, however. Not all the lights in a particular string will be used, so there
are many LED lights that need to be taped off and left unused on the back of the panel. It's back breaking work. And the panels are getting heavy! But they are going to look so good!
Taping Off Unused Bulbs
As mentioned above, any LED lights that won't be used must be taped off so they aren't visible. There are a lot of strings used in the Belardo Fireworks,
so there are a lot of unused bulbs that need to be taped off. We start that part of the process on the first panel on Friday before Saturday's lightup!
Look At The Pretty Fireworks Panels!
From concept to production, here is what a finished Fireworks panel looks like. There are 21 wires that need to be connected to the controllers, and a few
last minute wiring issues that need to be straightened out. But, in the end, both panels work, and the second panel was finished about 3 hours before lightup. That left just enough time
to go into the song sequences and add some Belardo Lights Fireworks programming. It was a little bit of trial and error, but we were able to refine the programming over the course of
several days and make it look pretty good! In the end, it was a very difficult project from a design and fabrication process, but it turned out and works well. We've received many
compliments from display visitors about the Fireworks panels, so in the end I think it was a success! Another example of how we "Dream Big" at Belardo Lights!
All Lights On For Testing
Here's what a Belardo Lights Fireworks Panel looks like when all the lights are turned on. Pretty colors! And our programming makes them come to
life during the songs at just the right time! You'll have to pay us a visit this year and see the new Fireworks Panels in action...
Dedicated To Brandon And Stephen!
Finally, a photo showing the whole package. The Fireworks Panels, and the rewired Brandon and Stephen panels as well. We dedicate our display to the
boys, with love! We're all about making memories for our family with the display, and we hope for your family as well. Thanks for stopping by the Belardo Lights display this year and we hope
you enjoy the Fireworks panels, as well as the rest of the display...