In this project we will walk through creating a foam core lamp bracket as an alternative to the 3D printed version you see in the images above.
Let's get started!
Step 1: Materials
- Foam core board (min 80mm x 40mm)
- 1 - Ruler
- 1 - Pencil
- 1 X-Acto Knife
- LED for sizing hole in platform (the green LED is my spare. I used it for sizing the hole. The final LED is red)
Step 2: Cut the Pieces
Measure a 40mm x 80mm rectangle, then measure two 40mm x 20mm sections inside the 80mm length.
Cut as seen in the images above.
The two smaller pieces (40mm x 20mm each) will become the clamps that wrap over the rink wall to hold the bracket on the wall. The remaining piece (40mm x 40mm) will become the platform that holds the LED.
Step 3: Attach the First Clamp
Apply a small amount of hot glue along the long edge of one of the small pieces from the previous step.
Attached it to the edge of the platform at a right angle (90 degrees) to the platform.
Step 4: Attach Second Clamp
Located a scrap of foam core that can be used to temporarily represent the rink wall. You can use a piece of scrap to ensure the clamps are close enough together to apply enough pressure for the clamp to stay attached to the rink wall during play.
Apply a small amount of hot glue along the long edge of the remaining piece (40mm x 20mm) of foam core. Sandwich the temporary rink wall between the two clamps and squeeze a little while the glue sets.
Tip: Be careful that glue doesn't seep under the temporary rink wall. You DO NOT want to glue all 4 pieces together.
Once the glue has set, remove the temporary rink wall.
Great work, almost done.
Step 5: Create the LED Opening in the Platform
Once all the glue has set, flip the bracket over so you are looking at the bottom.
Mark where you want the LED, I placed mine about 10mm from the edge and centered on the platform.
Use your X-Acto knife to gently drill a hole through the foam core. As you drill make sure to poke all the way through the foam core. This will leave a small opening on the top of the platform you can use to expand the hole from the other side of the bracket.
As you drill it is important to test the fit of the LED, you want the hole large enough that the LED fits, but not so large that it doesn't hold the LED.
Place the LED in the hole and trim any remaining scraps from around the LED.
You are now ready to mount your LED and Light the Lamp!
Step 6: Attach the Lamp to the Rink Wall and Test
You are now ready to attach the bracket to the rink wall and insert your LED.
Once everything is in place, you can Light the Lamp!
Job well done!