Introduction: Industrial Cast Iron Pulley Edison Lamp - Metal & Woodworking How To

Picture of Industrial Cast Iron Pulley Edison Lamp - Metal & Woodworking How To

In this video I make a pulley styled lamp from an old treadle sewing machine base.

This is a pretty straight forward project. I tried to cover all of the steps to make it achievable for just about anybody.

Step 1: The Video.

Here's the accompanying video for the project.

Step 2: Disassemble the Treadle Base

Picture of Disassemble the Treadle Base

First I disassembled the old treadle base to get to the middle section and pulley. The side panels of the base were cracked so the casting was no longer good for supporting a table.

Step 3: Remove the Pulley and Arbor

Picture of Remove the Pulley and Arbor

I removed the pulley wheel and extracted the center arbor. Then I looked for a good location for the pulley. Locating it on the center truss portion of the treadle base can be tricky. On this project there was a threaded knob that I worked very well as a mount.

Step 4: Find a Bolt for the Pulley

Picture of Find a Bolt for the Pulley

I found a old bolt in my scrap bin that matched the threads. I had to cut it down with my hacksaw to make it fit.

Step 5: Installing a Bushing

Picture of Installing a Bushing

The center arbor location need a bushing. I also found the bushing in one of my parts organizers. The bushing allowed me to mount the pulley firmly.

Step 6: Cut the Cast Iron Truss

Picture of Cut the Cast Iron Truss

I found and marked the appropriate location to cut the truss. I also used my right angle grinder with the DIABLO Round Corner flap disc to reproduce the original profile in the casting.

Step 7: Find the Length of the Wood and Locate the Bolts

Picture of Find the Length of the Wood and Locate the Bolts

I placed the cast pulley assembly on the plank of wood to find the correct locations to cut and drill. I used the original bolts to mount the cast assembly.

Step 8: I Used the Original Bolts

Picture of I Used the Original Bolts

In order to use these tapered bolts I had to countersink the back of the wood plank. I used a 3/4" countersink bit.

Step 9: Cut a Channel for the Cord.

Picture of Cut a Channel for the Cord.

I cut a channel into the back of the plank to make room for the lamp cord.

Step 10:

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I used a common keyhole router bit to cut the keyhole mounting locations.

Step 11: Distress the Cut End

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The cut end was too new looking. So I distressed it with a rock. I used stain and a black Sharpie marker to match the rest of the plank's surface.

Step 12: Sand and Finish

Picture of Sand and Finish

I lightly sanded the lumber to remove loose wood. I then applied two coats of water based polyurethane (satin) to both sides.

Step 13: Paint and Assemble

Picture of Paint and Assemble

I painted the cast iron with satin finish black spray paint. After it dried I began to assemble the lamp.

Step 14: Install the Lamp Cord

Picture of Install the Lamp Cord

I disassembled the lamp cord so I could fish it through the back of the wood. I located it in the middle so it would go up and over the cast pulley.

Step 15: Glue the Lamp Card

Picture of Glue the Lamp Card

I glued the lamp cord in place with a high-temp hot glue gun.

Step 16: Locate and Test the Bulb

Picture of Locate and Test the Bulb

I glued the lamp cord so it would come out from the middle of the fixture and go up and over the cast pulley.

Step 17: Finished Project

Picture of Finished Project

Thanks for reading. Here is a list of tools and supplies I used.

(affiliate links)

SAWS AND CUTTING:

▶ High-Tension Hacksaw http://amzn.to/2cM3T7W

▶ 80 tooth finish blade http://amzn.to/2dIteUO

▶ Chop saw http://amzn.to/2dItFyf

▶ Porter Cable Router http://amzn.to/2y7cDSe

▶ Keyhole Router bit http://amzn.to/2ywY3oi

FILING, SANDING & GRINDING:

▶ ▶ DIABLO Round Corner flap disc http://amzn.to/2y6ZFnj

▶ DIABLO 4-1/2 in. Metal Cut-off disc http://amzn.to/2ywITQb

▶ Milwaukee Cordless 18v Grinder http://amzn.to/2ywJ0Ll

▶ 10" Disc Sander http://amzn.to/2l7j26o

▶ SandBlaster - http://amzn.to/2yL1zbT

▶ Rock - FREE

HAMMERS AND POUNDING:

▶ Ball Pein Hammer http://amzn.to/2yOciS5

DRILLS, BITS and DRIVERS:

▶ High-Speed Steel Drill Bits http://amzn.to/2c9pX0k

▶ Milwaukee Drill Combo Kit http://amzn.to/2cOGXaH

▶ Tap and die set http://amzn.to/2epGN7D

▶ Countersink Drill Bit http://amzn.to/2y7baLF

▶ Craftsman Screwdriver Set http://amzn.to/2y7iHu7

PENS/PENCILS AND MARKING:

▶ Mechanical Pencil http://amzn.to/2dB6X71

▶ Silver Sharpie Marker http://amzn.to/2yybCE0

RULERS AND SQUARES:

▶ Tap measure http://amzn.to/2ddgDDW

▶ Swanson Speed Square http://amzn.to/2eE8BqC

SHEARS, SCISSORS & CUTTERS:

▶ Diagonal-Cutters http://amzn.to/2l7xonn

▶ Rebar cutter and bender http://amzn.to/2e1eH4B

▶ Titanium Shear http://amzn.to/2l2EYnh

CLAMPING, VISES and GRIPPING:

▶ Bench vise http://amzn.to/2dXysZB

▶ 6 inch bench vise http://amzn.to/2l2LwSW

▶ Channellock 12-Inch Pliers

WELDING, BRAZING & SOLDERING:

▶ Turbo-Torch http://amzn.to/2l7wnM5

FINISHES, PAINT AND COATINGS

▶ Minwax Polycrylic Satin http://amzn.to/2nJYiTf

▶ Rust-Oleum Satin Black http://amzn.to/2xpRIv3

PARTS AND PIECES

▶ Hanging Light Cord Kit http://amzn.to/2yvLuJX

▶ Edison Light Bulb http://amzn.to/2y76Z2A

Comments

DIY Hacks and How Tos (author)2017-10-14

Awesome. I have an old sewing machine with parts just like this. Now I just need to convince my wife to let me take them apart.

That might be tough. Craigslist is always an option.;)

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