Step 8: Assembly Summary and Tips
Pre-sand all your parts.
I used wood glue primarily to hold the parts together. When required, I also used brads to help aid in the assembly of the 5 pieces to keep them in place. 2 straps were also used to go around the entire shade to hold everything tight. If your lamp frame part is not a perfect fit cut it to size accordingly. The frame will assist in making sure all 5 sides are the same instead of relying on the mitered anges from each litho frame. Once the glue is dry, attach the trim molding around the bottom of the shade. The top-cap can also be glued to the top of the shade. - The spindle can now be installed to the top-cap. Install the lithopanes or diffuser material in the recess of the litho frame and secure with a small bead of hot glue.
The gear train assembly may look complicated but it is relatively straight forward assuming you cut out the gear moount correctly, every thing should line-up. To begin, press in the 1/2" plastic spacer into the 1/2" center holes in 5 of the 6 gears. The sixth gear should have a 3/16" hole to press onto the motor. Glue one 6 tooth gear to one15tooth gear so you will have two gears joined together. In the picture below showing the bolts thru 2 gears, the bolts are only used to keep the gears concentric.
The bolts for the gear train are to be used with washers and held in place on the opposite side with a washer and nut. The height of the seconday nuts (and washers) that stand off the gears should be approximatly 1/2" apart but you can easily adjust as needed. these are in place so the gears do not rub against each other while turning.
Attach the 'mount suppor't parts to the base using the #8 wood screws. Once secure, remove the gears from the 'gear train mount' and attach the 'gear train mount' to the opposite end of the 'mount supports' using the same type of screws. replace the gears and if you have not done so yet, apply the friction gasket to the top most gear using a spray adhesive.
The electrical design is to use a lamp power cord with a rotating switch or similar and wire both the light bulb housing and the wall wart to the power cord, this way both the light bulb will light and the lamp will rotate without the need for separate switches or 2 power cords going to the lamp. Install the lamp hardware and secure the bulb socket to the top. Feed the wire thru the extension and attach another short wire that will go to the wall wart. The bulb socket should have screw terminals where both wires will attach. The wire to the wall wart will need to be soldered to the terminals. The wire from the wall wart can be secured to one of the mount supports and hot glued at a few places to keep the wire secure. Cut the wire to the proper length and solder to the motor. The motor can run forward or backwards so decide which direction you want the shade to spin. Ensure both lamp, motor and switch works.
Choosing the right finish:
Hardwoods accept transparant stains better than softwoods whereas softwoods look better natural or painted - maybe a solid stain or whitewash. For this lamp, I chose to keep it natural and used a wax with orange oil (found in the staining section of the hardwood store).
The lamp shade can now be installed onto the base. You may need to balance your shade - do so by placing nuts or bolts on the inside frame support next to the diffusers. Enjoy.