Step 4: Modifying the Pull Chain

For the LED to fit in the hole in the metal part of the pull chain handle a bit of material must be drilled out. Doing this prevents the ball chain connector from holding the handle on the pull chain so it is necessary to use a small amount of JB Weld to epoxy the connector to the handle. I affixed the connector to the handle such that the LED's wires can pass through the connector's hole. The epoxy needs to set before continuing. Next I soldered a two lengths of wire wrap wire to the LED's legs so that it could be inserted into the pull chain's handle and reattached to the circuit a greater distance away. I marked one of the wires with a black sharpie to make clear it was attached to the cathode. I used hot glue to insulate the solder joints. After that I threaded the wire through the handle and three pieces of heat shrink, which were on the pull chain. Clear heat shrink would be better, but I only had green. Sewing thread can also be used to attach the wire to the chain, but it caused the chain to kink more than I liked. Attaching the wire to the chain is easiest if the chain is pulled tight. Once I had the pull chain modified, I connected to the lamp and threaded the wires into the diffuser bowl. Doing this allowed me to see how much excess wire I had. Next I took down the pull chain, trimmed the excess wire, discarded the excess, and soldered on two individual, male header pins to the remainder. Then I removed a bit of material from the top of the translucent plastic handle so that it would mate well with the LED. Finally, I inserted the translucent plastic handle.
Good job!
This is pretty low-volt stuff. Telephone cross-connect (red/white) is fun, but I would be you could achieve a little more elegance in this solution with ultra-thin urethane varnished copper wire.
That is an interesting suggestion. Don't you think the pulling motion would wear away the varnish though.<br><br>I'm currently working on an updated version where I put the circuitry in the diffuser bowl. So look out for it!
If you drilled a hole (or fit them thorugh an existing hole) in the metal at the bottom of the light shade, and put the solar panel at the top of the fixture inside (where the silver foil type stuff is), then it would have almost no effect on the outside appearance, nor on the light given off, and would still function almost the same (you might consider putting the battery on the other side of the foil / insulation, as I bet it gets pretty hot inside that lamp shade).
Many if not most fan/light installation are controlled by wall mounted light switches, and that may be why manufacturers don't design in light pulls. Lighted wall switches are a readily available item. A clever idea,and a good instructable. Good luck in the contest.
Where would I find the translucent handle?
Found it! I'm not the one that purchased it and I've had it for years but I'm fairly certain this is it.<br> <br> <a href="http://www.lowes.com/pd_101858-1811-FP5_0__?productId=3122015" rel="nofollow">Harbor Breeze Brushed Nickel Ceiling Fan Pull Chain (Item #: 101858 | Model #: FP5)</a>
A+ for ingenuity. F- for aesthetics. Would depend on the fan/light assembly but a larger fan/light enclosure could potentially house all the parts without creating a shadow. <br><br>Nonetheless, I agree with the other posters. This is a fantastic idea.
you could always use led bulbs<br>
+100 points if you could thread the wire through the glass, and stash the solar cell in such a way that it lives inside the dome, without making a shadow on the glass. <br>Coat hanger + hot glue maybe?
Otherwise, an amazing and beautiful project. I'd even consider manufacturing them.
Thanks very much!
In all seriousness, you could make a crapload of money off of this if you managed to market it. Even if you just sold kits it would help. Amazing project man.
Putting it inside the bowl was my original plan, but I had difficulty figuring out how I should place it in there and how to run the wire to it. Plus I thought it'd be a fire hazard putting it so close to the hot light bulbs. Thanks for bringing that up I'll edit the instructable to explain my reasons for placing it on the outside of the bowl.
Use CFL bulbs. master mode: crack open a CFL bulb, and wire up a ~5v output.

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