Introduction: 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
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
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
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
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
Step 7: 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
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.
I cut a channel into the back of the plank to make room for the lamp cord.
I used a common keyhole router bit to cut the keyhole mounting locations.
Step 11: Distress the Cut End
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
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
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
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
I glued the lamp cord in place with a high-temp hot glue gun.
Step 16: 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
Thanks for reading. Here is a list of tools and supplies I used.
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