Build a DIY Solar Path Light

Using a miter saw and the cut list above, cut the parts to length. Apply a bead of glue to both edges of two 1 x 4 boards. Sandwich the 1 x 4’s between square dowels, positioned flush with the base of the 1 x 4. Using a pneumatic nail gun or hammer, drive 1¼” finish nails through the square dowels and into each 1 x 4.

Stand the remaining two 1 x 4’s on edge on the work surface. Apply wood glue to the edge of each 1 x 4. Cap the boards with a wall assembled is Step One, positioned so that the 1 x 4’s set flush with the edges of the assembled Wall. Repeat to attach the remaining assembled Wall and to finish the Base.

Remove the base post from the light and discard. Unscrew the cap and remove the decorative lattice from the light.

Using a straightedge, mark lines that run corner-to-corner on the 1 x 8 Cap to create an X, crossing in the center point of the cap. Place the base of the light upside down centered on the Cap. Using a pencil, outline the light. Marking the Cap this way will allow for the light to drop down into the Cap—with the top of the light resting above the Cap. You can also opt to cut the hole to the size of the top of the light’s cap. Marking the hole at this larger size will allow the light to lift up through the hole and set flush with the surface of the Cap (though it should be bumped up a bit to avoid water pooling on top of the light). Note that this installation requires a tapered cut if the edges of the light’s cap are angled, and also requires glue to secure the light in place. Additionally, I caulked around the edges of the light to fill the gap and prevent rail from falling into the center of the light. Which is all to say, although I’m showing the installation of the light’s top sitting on the wood Cap, I ultimately recut the hole so that the light would set flush.

Using a drill/driver, drill a pilot hole inside the marked circle. Insert the blade of the jigsaw into the pilot hole, and then cut the circle.

If you want to remove the decorative lattice like I did, clip the plastic just below the top ring. Save the top ring, since this is the part that secures the light’s Cap to its clear Base.

To keep the Cap removable, reattach the ring to the Base using a hot glue gun and glue sticks. If you left the lattice attached, you can skip this step.

Using a lint-free cloth, high-quality synthetic bristle brush, or a sponge brush, apply a liberal coating of wood stain to sides and cap of the light—working in the direction of the grain. I used Varathane 3x Wood Stain in American Walnut. Additionally, coat as much the inside of the assembly as possible.

Using a lint-free cloth, wipe the surface in the direction of the grain to remove the excess stain. Allow the stain to fully dry.

Using a high-quality synthetic bristle brush, apply a topcoat in the direction of the grain. I used Varathane Spar Urethane in a Satin Finish. When possible, work in long straight passes to ensure a uniform finish, and tip off edges with the brush held at a 45-degree angle to prevent drips.