This is one of the many coconuts I ate lately. I already had most of the supplies at home so I tried to make this desk lamp and I hope you like the result too.
Step 1: Tools & Supplies
- Coconut shell
- Popsicle sticks
- Cardboard box (polygon)
- Roasting sticks
- Wood glue
- UHU general use glue
- Hex bolts
- Wing nuts
- LED Lamp E14
- Bulb socket E14
- Rotary tool + saw blade
- Cutter knife blade
- Sandpaper (80, 180, 320)
- Solid wood boards
- Drill bits
- Coping saw
- Glue gun + glue sticks
- Soldering iron
- Right angle
Step 2: Popsicle Sticks Layer Guide
Draw a 45 degrees angle on a thick cardboard and cut it out to use that space as a guide to glue the popsicle sticks.
Step 3: Forming the Layers
Make 5 long and 5 shorts layers. Each long layer has to be made of 16 popsicle sticks and the short ones out of 5 sticks.
Step 4: Make the Layers Rectangular
Cut the triangle at the end of each layer and glue it on the opposite edge to form rectangular layers.
Step 6: Gluing the Layers Together
First sand the layers to even them out and then glue them together with wood glue and press it on a vice, between two thick and solid pieces of wood. Use two clampses to add more pressure at the two edges. To add more strength to your wood, glue the popsicle sticks cross grained. Leave the wood glue to cure completely before cutting or drilling your pieces of wood.
Step 7: Drawing the Lamp Arms
I tried to use all the available space on the piece of wood I made, so I drew two parallel lines at the two edges and then I separated them with a line in the middle and form two equal pieces (arms). Then I formed a square at every end. I found the centre of the squares and marked a cross for the holes. For the design I wanted the arms to have a space in the middle but you could keep them solid.
I did the same, without the space in the middle, for two shorter pieces, that will be assembled at the top and the bottom of the lamp. The one of them will be glued on the coconut shade and the other on the base.
Step 8: Drilling the Holes
Use a very small bit to mark the center of the holes and then use bigger and bigger bits, until you reach the desired diameter. Drill 4 more holes to cut the spaces in the middle of the arms with a coping saw, or with a scroll saw, if you have one.
Step 9: Cutting Out the Lamp Arms
With a coping saw (or scroll saw) cut all the pieces. I used a 3V coin battery to add some radius on the corners. I marked the lines and then cut and file them. At the end, sand all the pieces and finish them if you want (i did't).
Step 10: Assembling the Arms
To assemble the arms use 3 hex cap screws (4.6), 6 washers and 3 wing nuts. The washers have to be between the wood and the two ends of the screw.
Step 11: Base Support
I made a support out of popsicle sticks that will go in polygon base and glued on it the lower piece of the lamp arms. (see photos)
Step 12: Polygon Base
Decorate the top of the cardboard box with popsicle sticks and the sides with roasting sticks. Make a hole for the switch and two small holes for the wire.
Step 13: Coconut Lamp Shade
To cut the coconut shell use a saw. File the edges to be more smooth and then drill a hole on the centre of the other side and file the edges until you reach the desired diameter, so that the bulb socket fit in it.
Step 14: Adjusting the Bulb Socket
To adjust the bulb socket use hot glue and then fasten it with a threaded nipple an a nut. I used an extra rubber washer, because the coconut wasn't even and I couldn't file it more.
Step 15: Gluing the Coconut Shader
To make the hole for the arm piece on the coconut, use a drill with a small bit and drill all around the frame that you drew. When the piece fall off, use a flat file to reach the desired size. Try not to make the hole bigger than it should be, so that the wooden piece of the arm fit tight in it. When you fit the piece in the desired position glue it with wood glue.
Step 16: Wiring the Socket, Switch and Plug
Leave the socket's cap screwed in the coconut shell and take out the socket interior. Strip off the insulation of each wire. Unscrew the screws of the socket interior and connect the hot terminal (the one that is connected with the central contact of the other side) with the brown wire and the neutral terminal with the blue one. Put the interior's outfit on the cap and screw the socket's shell on it.
To connect the cord with the switch, put it in the base through the one small hole you've done in a previous step, strip it off and cut only the hot (brown) wire. Use an soldering iron to connect the two ends with the switch.
Take the cord out of the base through the other small hole. Strip off the wires, unscrew the plug's screws and then tuck the wires by screwing them back.
To learn all about lamps and wiring enroll to the Lamp Class.
Step 17: Enjoy the Light
Now that your lamp is ready, you can screw your bulb into the socket, plug it in the wall socket and turn the switch on!
If you are wondering if I bought all these popsicle sticks, let me tell you that I ate all these ice creams! Hehe
I hope you liked that idea and if you'll try to make it, choose a bigger coconut or a smaller bulb! :)