Mosaic Solar Pole

Instructions for building a Mosaic Pole with solar lights inside.
Below is a list of the material I used, based on what we had around the house and what could be ordered if not available in town. I am providing affiliate links to Amazon in case you want to order. To be honest the hardest item to find were the solar lights that go into the center, I tried a few before finding ones that were bright enough. I also wanted to thank Sue Smith Glass for all of her tutorials and information, she definately inspired this project.
Pattern- Created in Photoshop using photos I took and images of flowers/butterflys I found on the Internet. Once I was happy with the design I went to my local print shop (Post-Net) and printed to actual size then had them laminate.
Glass- The panels are double strength glass cut into 4 equal pieces of 5" x 36" x 1/8". I wanted the edges round so my local glass shop cut and rounded the edges I decided on this size for two reasons: 5 inches- so with the clamps I could put the base of a 6" pole light cap over the top. Well I should have gone smaller because the pole was slightly to large once put together. So Gorilla tape to the rescue. 36 inches - so I could use two 6 foot 90 degree aluminum bars cut in half on each corner. Originally I was thinking of putting 1 inch on the outside and 1/2 inch on the inside for strength but decided against that and just went with the 1/2 inch on the outside.
Creating Mosaic- On a large worktable (plywood on sawhorses) I laid the laminated picture down and then the 5 glass panels so I could see the patter. The glass I used was regular stain glass, fused glass, and melted bottle glass including wine, liquor, and beer bottles. (Most of the green, blue, black and brown were melted bottles). I would grab a piece of typing paper and roughly drew the areas I wanted to work on so I could sit in front of the TV and assemble the flowers, bushes, etc. Once assembled I would use blue masking tape over the glass and move it from my workspace to the glass panels. I did not adhere to the glass until all of the panels were pretty well done. Carefully lifting/remove the taped pieces I would brush on Lexel and then replace the taped areas and remove the blue tape once glued on. Final step was to fill in areas I did not use tape for. There are more talented individuals that can free hand and glue as they go, I just know this way works for me.

Adhesive- Lexel Clear Sealant to adhere glass to glass. Can also buy in your local hardware store (which I did). I did alot of research and thought this was the best for me, especially since our family owned a hardware store that carried it. Other brands can be used just make sure it is waterproof and weatherproof.
Grout- Prism Charcoal- indoor and outdoor and can use in wet/submerged areas. I have used this grout on my other projects and really like putting it on using the dry method (grout is wet but wipe off with dry cloths.)
Top L glass clamp for four panels, no holes- these go on the top of the four panels. It is much easier to have two people when assembling.
Bottom L shape glass clamp with holes for securing to base. These go on the bottom of the four panels.
1/2-inch by 1/2-inch Angle 90 degree aluminium bar- these go on the corners of each panel and inside the L clamp.
Double face Heavy Duty Tape- small pieces go on the bottom of the L clamp with holes so that when you put it on the wood base the clamps will stick to the wood for helping with placement.
To assemble- hold two of the panels at a 90 degree angle and place 1/2" aluminum angle bar along the seam of the two panels. Then place the the top and bottom L clamp on the corners with the angle bar in the L. Tighten the clamps screws on both the top and bottom. Continue with the other panels which will result in a square. When complete stand up and make sure it is what you want. Wrap Blue tape around the bottom to hold the glass and aluminum bars in place. Once satisfied, lay back on the side and place double face tape on all the bottom of all of the bottom clamps AND loosen the bottom screws so when you press the 10" x 10" wood against the bottom you will be able to slide the clamps and wood off. Then screw the L clamps onto the wood block. Once set, place the wood and clamps back onto the bottom of the pole and tighten the screws by inserting your hand through the hole. (Using a shorty screwdriver works best.)
Tree Slice Heavy Base- Last year we had wicked winds that ripped through our city taking down thousands of trees. We kept a few slices for possible projects. Since the slice was very heavy we decided to use a large tree slice for the base to ensure the pole would not be blown/pushed down in the future. During drying a large crack formed which worked well for hiding the solar light cables.
Wood Square 10" x 10" x 1 1/2" (WITH HOLE IN THE CENTER)- Small Base that the L shape Clamp with holes are screwed into and then screwed into the large tree slice. This wood square was not in the original plan until we were getting ready to attach the L clamps to the tree slice and I realized that I would not have a way of tightening the screws securing the glass in the L shaped clamps. After brainstorming and seeing what we had in the garage we used a 10 x 10 square and then cut a 4" hole in the center so that once the L clamps were attached to this base we could put the base on the glass and tighten the screws that hold the glass by sticking my hand in the whole. This also worked well for feeding the solar light cables through the base.
Stainless Steel Screws - 4 were used to secure the 10 x 10 wood to the large wood slice
Solar Lights- two in one- these are the brightest I was able to find- can dimm to 1/2 strength. I placed one light in the bottom facing upwards. The other I attached using floral wire losly to the bottom of the post light using the little holes that were for the screws (which I did not use)
Solar flame Light- placed on top of the pole using Gorilla Tape- since the pole ended up being wider and resulted in the large base not fitting over the top of the pole.
Gorilla All Weather Tape- Black - ended up using the tape to secure the solar pole light to the top and keep the rain/weather from gettng inside the pole. Also to keep the light from shining out at night.

Instructions for building a Mosaic Pole with solar lights inside.