Assessing The Show

So, the self assessed B grade, why so low?

It is a considerable shame that something I worked meticulously at for weeks came down to a scrambling, harried finish. Can't help but think it could have brought more satisfaction had I properly budgeted time, and had enough of it to double check every connection. Every rack should have been built prior leaving only visco connections for the day of. I really have no excuse for not completing these except that the sheer scale of the endeavour should have warranted some kind of record keeping or 'to-do' list that could have been checked off.

The few I've confided this concern to, stated they wouldn't have noticed any difference had I been 100% ready. It's likely I'm my own worst critic. However, small gaps in the show and the fact I could barely understand the instructions I wrote for myself, meant timing deviated from plan more than I wanted.

The self-instructions I created to prompt cue ignition were based on having a complete understanding of which item was active at any given time during the event. This is more difficult than it sounds, the time goes by very quickly! I got lost twice. Having reviewed videotape, I was lost once because two items were nearly simultaneously ignited (visco error or ignition via fallout) and another because I didn't know which item was presently being fired. This led to me looking at my cue sheet far more than I wanted to, drawing my attention away from the display.

The Canada House fountain was lit up manually, crackled for a bit and promptly fizzled out, not exploding violently as planned. Going up to manually light the circus wheels that should have led away from the Canada House wreckage was a bummer.

Eight total items failed to ignite. Six due to visco connections that didn't take, and two that took but didn't explode (duds). Three of these were fairly integral items, a Big Bertha cake (solo firing, leaving a hole in the show), a Silver Shrapnel mortar and Jumping Jelly Beans, a pretty cool fountain. We exploded a couple of these after the show.

Back to the B grade; Why so high?

While the mad dash to the finish line was aggravating, some of the time consumption was beyond my control. Some slack must be cut.

The show was an experiment of sorts, and the audience seemed quite entertained by the result, which I am very pleased about. I'll allow myself more slack as it is a first time using electronic ignition. If I were a spectator unconnected to this project, my grade would probably be considerably higher. Perhaps I shouldn't force mathematics upon what is essentially an art form. Paul put it in perspective by saying it is near impossible to rehearse. Very true.

That said: I predicted a show lasting 17 minutes and 15 seconds. The result was 17:06. Not bad, actually pretty damn good!

The eight total ignition failures represent less than 2% of the total, a number I can live with. The Schwartzvolcker system worked perfectly as well. Every cue called upon to fire did so, and quickly. This I am proud of.

There were some very intense points during the show that awed me, and the reaction from the audience during these points made up for the issues.

*  *  *

Two cameras were set up at the site. A wide angle GoPro was set back almost 50 feet to capture aerial effects; the same camera used last year. Like a year ago, it was not angled sharply enough (Grrrr) to capture all of the highest items, though it is much better than 2011. The other camera was set up just far enough outside ground zero to view every rack while they blast away, about 15' from the nearest one.

The result is two videos. One shows the overall show presented with a picture-in-picture of the exploding racks, the other will be a subtitled narrative of the items going off, more for my own use in post-mortem but to be posted here in a while.

FYIs: The steady burning flame on the right is over the fence in the sewage treatment plant.. Due to the lens convex it looks tiny, but it's 15-20 feet of poo-gas flame! An apropos backdrop, if a bit gross. The fireworks being blasted off to the left throughout the vid are the folks who brought some items to donate - we couldn't use them since the show is planned - so they decided to blast away right there intermittently throughout the event. Unfortunately what was a thoughtful gesture became an annoying and somewhat disrespectful distraction.

The camera trained on the racks appears to have an autofocus problem. Though ok for 95% of the show, it went fuzzy right as the 60-shot air bomb rack blasted off. Bummer.

I recommended arrival between 9:30 and 9:45, but we didn't get going until 10pm for two reasons. In my opinion darkness is requisite, at 9:45 deep dusk still lingers. There was also a professional show that started at 9:40 about a mile away that was clearly audible and visible - this was welcome to prevent the audience at this show from getting too impatient!

*  *  *

Post show there was a small amount of excitement. During my goodbyes to the audience, and a full two minutes after the last item ignited, a mortar in the finale rack blasted off, surprising all. This highlights the inherent danger in approaching duds. The plan was to leave the racks alone for 12-15 minutes, ensure all were extinguished and pack up. About 6 minutes into this plan though, one of the Detonator cakes erupted into flames, getting the kids pretty excited. No big deal. It was fully extinguished (along with a few other smouldering items) and left to sit.

Wiring was rounded up, racks tossed into the truck, cameras and kit were packed and loaded. Got some curious looks driving home.

I returned in the morning to clean up the site. Being made of paper and clay, fireworks ejecta is typically bio-degradable (with the exception of the plastic plugs in some mortars). However it is common courtesy to return in the a.m. to clear up the little bits and pieces. Why give more ammo to the naysayers and zealots?  It is a public space after all.

I spent some time hammering clay out of items made only with paper; the clay was swept into a dead zone behind my shed, and the paper got recycled. Ran the last load to the end of the driveway just as the truck pulled up; after looking at the stacks of fireworks the driver asked if I was the reason the bomb squad was out, having seen the commotion on the evening news. We shared a laugh as I watched the husks of my labours tossed into a heap in the back of the truck.

*  *  *

This post was late since I worked hard on a continuous video of the show; unbeknownst to me YouTube accepts a maximum video size of 15 minutes. It was re-done to post here, but not quite as polished...


Special thanks to Paul for his help.

Canada Day

Happy belated Canada day to all!

Ground zero was re-conned in the morning; didn't look like any events (sports tournaments, picnics, etc) were set up for the day. Phew.

Kept an eye on the weather radar all day long. At around 4pm it looked as though we were going to have some early evening showers but they didn't materialize. Phew II.

*  *  *

Visco wiring starts after lunch, far too late. We work at a furious pace for almost six hours straight to get everything prepared. I had originally budgeted 4 leisurely hours. There were also a few extenuating circumstances that put a dent in overall preparation, such as the bomb squad dealing with a scare directly across the street. Not kidding.

Thank goodness for Paul's presence; he is a champion tech after getting a crash course.

I'm annoyed to discover I had not built two planned racks (60 shot air bomb & Carmel fountain rack), The air bomb rack is put together, consuming more valuable time. We decide to wait on the Carmel fountain rack.

The time consumption comes from the constant translations of time into visco length, and regular check and re-check of the plan. Then there's getting underneath pallet decks to wire up from below.


We call last week's impulse purchase 'Canada house'. After the fountain effect it supposedly glows the word CANADA through the box. We decide that we want it to explode after doing this, so it is loaded with shotgun shells:


By 6:30pm all five racks are complete, along with six additional items that are not fixed to the pallets, rather on their own  - but connected by visco. We are feeling hungry and spent. Carmel fountain rack does not get built. The truck is loaded up so full the seats must go all the way forward. We're both over six feet and exchange some laughs at how ridiculous it is. 


We break, eat and hit the road for ground zero. Here we don't have to rush, there's 45-50 minutes of daylight left. Turns out we need every one of those minutes. We start by determining wind speed and direction, from there it is crowd placement and camera angles.

The Schwartzvolcker is unpacked. The junction box is placed at ground zero and all five pallets are oriented in a circle around the jx box. The plan is to have the show go in a counterclockwise direction around the center.This will also avoid crossing cables.

All e-matches are attached, and the ignition panel is set up. Continuity tests ok on all cues. Some folks show up early and want to wander around so we place cones out. Some even wanted to donate fireworks to the cause which is generous, but given the planning that goes into this we are unable to accept the offer.

Colour codes are double checked, and exposed visco is wrapped in tinfoil.


The location is perfect. Yes, there's the odd nasty sewage smell drifting over from the treatment plant, but it is a sleepy industrial park about 1km from the nearest house.

I'll post tomorrow about the show itself, as the video is still 'optimizing' on the Mac.

Everyone left happy, and i'm overall fairly pleased. I give myself a solid B grade for the result, details to follow.

5 minutes after the last item goes, the smoke still lingers.
The morning after.

Apparently the weather might suck:


So a 30% chance of rain is a 30% chance the show will be bumped? I guess if one were betting, this opinion would be analyzed. It states 'showers', which by the definition I understand are those 5-15 minute precipitating cloud banks that pass occasionally on an otherwise hot sunny day. So a 30% chance that showers will appear SOMETIME during Sunday is actually pretty good odds we will be dry between 9:45 and 10:15PM, right? Is this correct?

Then why the stinking, grey-cloud rain graphic? Why does the human race tolerate weather forecasting when we get so pissed off about a bus that's 5 minutes late?

On this here eve-eve I'm a little anxious that I may have forgotten something, particularly since I already discovered a few things tonight that I forgot. It was a bit of a mind bender plotting all the items, an inventory of sorts, then comparing to the plan and seeing that some predetermined cue points didn't really add up. There were also a few little racks that didn't get built, and the sheer volume of fireworks that need to be visco-wired is a little whelming. No rest...

All racks are loaded.
My great friend Paul will assist me on Sunday. This is essential for a number of reasons. The most important, to double-check each others' work. There isn't a large amount of skill in what's being done here, but visco wiring is a monotonous task that is time consuming, these two ingredients are key to glitch cocktail. A second set of eyes attached to an interested brain is most welcome.

Some of these racks are two-man lift, and at ground zero it is nice to have another opinion on variables such as rack orientation, wind direction, starting time, crowd control, troubleshooting, etc. There seems to be so much I have to keep in my head (paper will go only so far during the show), it is relieving to have a trusted resource to bounce these things off.

*  *  *

Finished loading all racks tonight. there are a few that remain, these will be adhered after fusing and are typically doubled-up items that share a single fuse. All that needs to be completed is the 60-shot Air Bomb rack and a 12-shot Sky Rocket rack.


Discovered a funny thing about Menace, a cake I've used a few times before. It has a minor case of the need-to-appear-more badass-itis. I really don't get it.

It's only 25 shots, so why 36 tubes?
Seeing everything together gives me a good idea of how large ground zero will be. Given there are two slats that have over 20' available from the junction box (the other three are 12-15'), I'm wondering how far apart the racks should be spaced. Not sure it will really make a difference. Perhaps Paul will have an opinion on this.

No worries, BBQ tank is empty.
Multi-speed, visco length vs time calculating sheet.
We have to prepare for nine guests at our house and a party as well, so tomorrow will be spent largely away from this project though there seems to be things that need doing. Sunday is reserved for this.

Tomorrow is still special though, in that the bylaw says it's ok to blow off fireworks. In the evening we'll do just that, with a full-on test of the ignition system.

Pluggin' Away

The show order is final. The spreadsheet containing the original plan was modified (adding in the impluse-buy extras) and extended by two columns. One column contains the amount of time between electronic ignition and the remaining items in that cue (to determine type, cut length and install of visco fuses), and the other with operator instructions, such as "20 seconds after start of Rainbow Candles".

Looking ahead to the live show, I'll have to pay close attention to what events are occurring to make sure I stay within plan. Though I have some memory of individual items based on past experience and/or watching them on YouTube during the planning phases, the key will be noting when they start and end. Worst case scenario (operator distraction, visco failure) is a couple of seconds pass without any action - and the very next cue is ignited with the press of a button. Duds, whether firework or e-match, are worrisome. If an e-match is bad there will be a delay while the cue is manually ignited. It may be skipped over depending on what it is. A dud firework is almost worse. If a solo, there may be up to 30 seconds of silence while the visco continues to amble its' way to the next item. Worse still would be a dud firework at the start of a cue; it may be difficult to tell whether the fault lie with the e-match or the firework without cautiously approaching ground zero for a look.

No real sense in worrying about this, I have to remind myself that this show format is essentially a first time effort.

The stats in the plan are interesting; there are 80 different events (not counting multiples) containing 437 items, with 3,038 individual shots. 264 of these items are either air bombs or candles. There will be no more than a 2-3 second break over a seventeen minute and fifteen second show. We shall see how close this is kept to.

The weather forecast continues to be positive, with little change from yesterday's. I'm pleased that Sunday is no longer book-ended by a potentially rainy Saturday and Monday.

*  *  *

Cake racks are prepared using a simple method. Bottoms are removed on each, and they are glued with PL (construction adhesive) in the marked out areas on each pallet rack. I had previously drilled holes where visco will run to each fuse from the cavity below the pallet deck. The paper wrap at the bottom of a cake is typically flimsy and will not hold a cake to the surface in the event it is knocked. Adhesion directly to the inner tubes is required. PL will glue almost anything to almost anything.


A couple of racks have all items mounted. In some cases a items can't be glued down, it would restrict access to the fuses. Adhesion will be completed at time of visco connection.


Wedge shaped shims are utilized to angle some mortars. these are fastened to the rack deck with screws.


Some housekeeping will be in order tomorrow; the workshop is trashed. I'll need some room for the racks, after they are mounted there's no tipping them onto their side to save room. Tomorrow I will check if I can obtain a trailer as well. I don't think all these would fit in the truck.

Forecasting Awesome

I typically ignore 7-day weather forecasts since they are like rolling dice. Starting to pay attention today though, and Sunday looks perfect:


Added a couple of items into the program (since the budget is blown anyway), spending another $37 on a few effects to augment the finale, and a special fountain to kick off the show.

Planning is now underway to determine what items are best to attach directly to ignition cues. There are twenty to use, but at least five should be reserved for the finale. Obviously distance between items has considerable bearing on this, it makes little sense to connect racks using visco, rather connect items within racks. Individual multiples being fired at once are going to be considered as well. I don't want to connect much more than eight effects with the slow burn visco to avoid any timing issues. Once this plan is determined, it will be used to wire up the visco on blasting day, and provide me with a firing menu that can be referenced during the show.

I've made some minor modifications to the overall order, but generally sticking to the initial plan. The show will kick off with some ground effects, then launch into a steady feed of individual effects for several minutes, interspersed with smatterings of air bombs, mines and mortars. Cakes with some of the best multi-effects will occupy the middle of the show before racks are ignited that run in tandem with each other. About two thirds the way in, mines and fountains will join the show for multiple heights of effects. Nearer the finale, up to six different items may be in the midst of firing at once.

Rack mounting work will begin shortly after the ignition plan is finalized this evening.

T Minus 6 Days

The heat is on. Focus must now be spread among a number of items on the to-do list, particularly anything needing testing / verification.

All bugs are worked out of the ignition panel. Instead of spending hours trying to figure out how the CAT5 dual receptacles mangle the electrical signals, they are yanked out and disposed of unceremoniously. Taking a closer look, the two jacks are tied in together on the internal PCB. Surprised I didn't see smoke in hindsight...


The jack is replaced with E-Z snap receptacles in both the jx box and the ignition panel. This has added $26 to the cost, almost doubling the original $60 budget, not to mention the painful waste of time.

The 20 speaker terminals ordered in were picked up yesterday afternoon; the salesperson asked "are they for fireworks". Interesting that others in the area not only build stuff like this, but obtain parts from the same supplier!

Attention is turned to creating the cue set slats, so more scrap wood is needed. 4 x 4 blocks will do the trick since they are reasonably heavy and will stand up to some mild abuse in the field. Five are cut to ~8" lengths.


Channels are routed out almost the full length of one side of each block. The channels will contain the cabling.


Diodes are soldered to the negative lead of each speaker jack. In a DC circuit diodes allow power to travel only one way (in the direction of the marking). In this case they will ensure the LEDs go out after each cue ignites, and better yet prevent leakage current from accidentally igniting other cues.


Each speaker terminal is installed in ascending order, keeping with the colour protocol on the RJ45 cable leading to the positive, and tying in to each diode with a single wire on the negative side.


Time to test when the first cue set slat is complete.


Testing goes well enough that four more slats will be built the same as the first, and the system will be ready for a full, 20-cue live field test this coming Saturday. I could not find the Predator e-clips at the local fireworks retail trailer, but they had Launch Kontrol ones that look very similar at the same price. These seem to work just as well.

The whole kit, minus four more 4-cue slats that must be made.
The final schematic, showing the changes in build drifting from original plan.
Apart from the upcoming field test, this will be all posting about the Schwartzvolcker before the big show. Barring some catastrophe, it will be charged up and ready to deliver a zap to the place I want when I want!

Tomorrow we'll turn our attention to loading up pallet racks and securing items prior to wiring.

Troubleshooting


A bench test with the entire system wired up, but testing individual cues, revealed a strange condition; on all five slats the first two cue LEDs were lit when either the orange pair or blue pair were connected (cues 1 or 2). Keeping in mind the following protocol:

Orange / orange-white pair = cue #1
Blue / blue-white pair = cue #2
Green / green-white pair = cue #3
Brown / brown-white pair = cue #4

This pattern was found at the output of the jx box. Testing at the output of the panel is even stranger, with LEDs 2 and 3 lit when the orange or blue pair is sampled individually. Again, green and brown (cues 3 and 4) remain in fine working order.


The panel is opened up, and the entire internal wiring build is compared closely with the schematic plan. Everything seems to match perfectly. The same test as above conducted at the internal wiring level (before the CAT5 receptacle) and it performs without flaw. The CAT5 box is problematic!

The receptacle is tested for continuity in two places: the strip where the RJ45 is punched, and the tines that make contact with the cable crimp connector. This test yields an interesting result, that the punched strip, labeled 1 through 8, does not correspond with the tines. More like:

Strip positions: 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8

which are cues: 1 - 1 - 2 - 2 - 3 - 3 - 4 - 4

coloured: O - Ow - Bl - Blw - G - Gw - Br - Brw

get moved to: 4 - 4 - 2 - 1 - 1 - 2 - 3 - 3

within the receptacle.

Assumed problem is sketched out, red ink indicates likely issue.
This seems to explain why orange and blue are affected. At some point, probably within the receptacle punching or cables that were crimped up, the blue/white and orange/white are crossed over between positions three and six. Thinking that each cue pair is simply doubled up for a halving of resistance, I need not pay fine attention to the pairing position! For example, orange and orange/white may have originated in positions 1 and 2 respectively, but terminated in positions 2 and 1 respectively, which would create a closed circuit for two cues due to the receptacle mixing up the pairing.

This theory is also supported by the condition found directly in the output of the ignition panel. By using the same receptacles on both transmit and receive sides, they should cancel each other out if the cables and punch strips are pinned out paying attention to the pattern with each pair.

The problem is with the cable as the testing seemed to indicate.  Pins 3 (blue) and 4 (blue/white) are reversed on one end. The end is snipped off, and re-crimped correctly.

One of these cables is not like the other...

The time consumption of this troubleshooting is costly, but I'm no data cable whiz, so as annoying as it is, it's still a learning experience.

Control Panel Nearly Done

The Schwartzvolcker project is nearly complete. All that remains are the five set slats that require backordered parts, among minor tweaks. Fingers crossed.

All bare connections in the control panel are soldered up, all screws tightened and all M/F joints are squeezed. Also replaced the sketchy home-made ATO fuse holder with a $3 automotive unit for peace of mind. The unit is sealed with screws, and lifted & shaken before the overall circuitry is tested. Test consists of continuity / LEDs lighting up when circuits closed (and off when open) on all four cues over all five sets, and 'ignite' (current spike) for all twenty combinations as well. Additionally, the charging circuit is tested, but not before adding a diode facing toward the battery (so current can NEVER flow to the speaker terminals on the panel). Everything bench-tests positively.


A plank of 1 x 8 is cut to about 14". Using a jigsaw, a hole is cut to allow an old dual CAT5 receptacle to be flush mounted.



The jx box is attached to the reverse side of the plank. 2 holes are drilled through the back of the box to line up with the receptacle. 12" pieces of RJ45 cable are pulled through and stripped to 3", inside the dual CAT5 receptacle. Each of the 16 individual wires are punched into their proper locations.

On the flip side, one of the RJ45 cables is stripped and attached to the 'positive' (cue ignite) posts according to colour protocol (previously decided as orange=1, blue=2, green=3, brown=4). The other cable is pulled through four 3/16" holes drilled into the jx box the the bottom right.


A mild annoyance with the project is that it would have been much easier if it were a 4x4 (16 cue) system; there are four pairs of wire in RJ45, and it seems most of my available accessories are tailored to it. Alas 16 cues is too few.

The four coloured pairs are connected to one side of a four-post electrical strip connector. The strip is then bolted to the jx box. These connections will be negative ground (set) wires, each individually returning power from whatever slat is selected in the five-position panel switch. They are labelled according to their set position. The CAT5 female receptacles do not need labeling since the positive power is supplied in four pairs controlled by the ignite switches - doesn't matter where they are plugged in. That said, it is critical the negative return wires are connected to the correct strip post!


The jx box is completely wired up and ready to close. Note the hole drilled beside the strip connector - Must make room for the fifth set's negative return wire, that will be run to the control unit (since there are only four pairs in RJ45).


Two additional planks are nailed in to the double sided junction, shown here in a field check. Cosmetics / finishing will occur shortly now that testing was positive. The plan is to cover it with another piece of wood to protect if from ground zero fallout and (God forbid) light rain.


Some stenciling is added on key areas of the panel. All that could be obtained within my budget (already blown, but $2) and timeline was the old Microsoft standby Times New Roman, in too large a font size. Other choices were "Princess" and something resembling the dreaded Comic Sans.

The on/off switch is already labeled, and the key switch seems obvious. Not sure much more can be applied without it looking too cluttered, so it is likely done.


Not much left on this project until the speaker terminals are received. After that it will need a full field test of all twenty cues, so I'm totally confident using this thing in the big show. Until then, the coming days will see some attention paid to securing items to racks. The goal is to be done everything except visco connection and ignition system wire-up by Canada Day, a mere 10 days.

Two Weeks Away

Though time is running down quickly, pretty sure I have enough of it to get everything done. The Schwartzvolcker Project has sure put a dent in the deadlines, though.

The control panel was completed, and the junction box started. From here, I'll need to complete the jx box and each of the five slats. The 20 speaker terminals had to be ordered in; they are supposed to be "about a week" as of last Thursday. I worry about this a little. I also need to complete rack preparation, rework the timing (of what were acts) into cues, and wire everything up with visco of course.

I was hoping to try another fountain wheel but this may be bumped in favour of the whole electronic ignition project. We'll call it #8 on the priority list for now. If it makes it to #1, it shall be done.

Wiring is completed in the control panel. Female/male connectors are utilized wherever it is deemed fit, i.e. removal of the front cover will be made easier if wires can be disconnected.

The shell is then installed in the original 'furnace efficiency meter' carrying case.


The panel is complete with the exception of stenciling, I'll have to drop by an art shop to obtain this. Not a fan of label-making, with that white background. I would like to add a slick, pro look to the unit, we'll see if this is feasible and cheap (broke through the $100 mark for this project late last week).


Outputs were fastened to the underside (rear, when in use) of the case using an old CAT5 box I had kicking around. 


The jx (junction) box was started from a Princess Auto six dollar clearance item. It has isolated electrical posts that can be used to tie multiple cables together. Four will be used for positive power (cues 1 through 4), and the other five for negative ground (slats A through E) creating the twenty cues. Sadly this item has only seven posts, so two will be home-made.


A view of the jx box faceplate - these five outputs will carry on to the five (yet to be built) slats. I'm still a big fan of this setup, and quite excited to see it in action. The jx box is to be 75-100' away from the control unit, and there's further distance and flexibility in the plug-in nature of each slat. Further still if the distance of each e-match is considered!


* * *

Had a look tonight at the fountain program that is to run in tandem with the aerials nearer the end of the show, and the mounting requirements of some of these items. 'Mad Dog' caught my attention. Presumably to look hulking or to justify its' MSRP, Mad Dog is packaged in a cone that is double it's necessary height, and over three times it's needed volume. Can't imagine what additional cost burden this would place on the importers of these things, all in the goal of appearing far more bad-ass than reality.

Stupid. 

To make it usable in my show, Mad Dog needs a rabies shot.

Cutting 'Mad Dog' down to size.