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As I said, I researched many different designs before I started and found that I preferred the infrared lamp as my heat source because, well frankly, I thought I'd burn my house down if I tried to build my own heating element. I even considered buying three electric pancake griddles, bolting them side by side into a box, and placing that over the plastic sheet. I tried it with one griddle and it worked pretty well, though my wife was not pleased with me disappearing into the garage with it. I used a total of ten infrared heat lamps that you can purchase at any hardware store. There are four 250 watt bulbs, six 125 watt bulbs, and one 1200 watt patio heater. I had the patio heater already so i incorporated it, but i'm sure I could have used 4 more 250 watt bulbs in its place. This gives me a total of nearly 3000 watts of heating.

The bulbs are mounted with ten porcelin standard 120 volt, 600 watt light fixtures. The kind you find mounted on a rafter in your attic, or in a garage, or basement. They do not have a pull string or switch built into them. When figuring the placement of the bulbs I had to take into account the thickness of the insulated panels, which I will explain later. I'll be upfront.this part worried me the most.

I would have liked to have used junction boxes and romex for all the wiring but I decided to throw caution to the wind when the budget ran thin. 40 feet of wiring cost $3.00 versus all the romex and junction boxes costing $60.00.

I did however oversize the wiring, and use a whole roll of electrical tape on each wire nut to put my mind at ease. I connected the wiring in three circuits to avoid tripping breakers in my house. One circuit is the patio heater alone. The second circuit is the four 250 watt bulbs in the middle. Ultraman cosmos. The third circuit is the six 125 watt bulbs on the outside. Each circuit has its own cord. This configuration was designed to minimize load on any one breaker in my house.

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I can plug the whole thing into my garage circuit, but I don't simply because I'm paranoid that the builders of my tract house did a crappy job with the wiring. This configuration has the added benefit of allowing me to control the heat required for different thicknesses and material types. For thiner materials I can just use the patio heater, or the patio heater and the four 250 watt bulbs. For thicker material I can turn on the six 150 watt bulbs. I mounted the whole thing on the bottom of an old janitors cart I had.

The bottom shelf serves as a cavity for the wiring to be stored and protected. Obviously particle board and enough heat to cook a turkey in about an hour aren't a good combination so I thought I should insulate the heat box. I found that the insulated panels would serve several purposes. First, they keep the particle board from getting too hot. Second, because the plastic sheet serves as a kind of cap for the heat chamber, the insulated panels help hold the heat under the plastic rather then letting it disipate into the air.