Introduction: Sombrero LED Man

I wanted to make a little bedside table lamp for my little sister. The eventual design turned out to be a sombrero LED man.
With Halloween coming up i hope it will scare some monsters away.

The design is based on two principles: easy to make and cost effective.

Total cost = $23,12

  • 3w LED: $3,5
  • 3w LED driver: $2,5
  • 9v power supply: $4
  • 12 ping-pong balls (you only need 1): $4
  • Wooden beam: $6,25
  • Aluminum bar: $1,87

 

Step 1: Materials and Tools

Materials:

  • Wooden beam (3.5 cm x 1 cm x 173 cm)
  • Aluminum flat bar (3 cm x 4 mm x 16 cm)
  • 3w LED
  • 3w LED driver
  • Power supply 12v
  • 2 screw bolts 3 mm
  • ping-pong ball

Tools:

  • Super glue
  • Wood glue
  • Wood paste
  • Saw
  • Jig saw
  • Sand paper
  • Wood clamps
  • Drill
  • Drill bit:  2,5 mm, 7 mm, 22 mm, 25 mm
  • Hole saw 90 mm
  • Solder
  • Solder iron
  • Thermal paste

Step 2: Sawing and Gluing

Start by sawing the following pieces of the wooden beam

  • Saw two 18 cm pieces
  • Saw two 25 cm pieces
  • Saw three 19 cm pieces
  • Saw three 9 cm pieces
  • Saw one 3 cm piece

Saw the 25 cm pieces into three lengths 11 cm 11 cm and 3 cm
Saw every piece in a 45° angle.

Saw the 18 cm pieces in to two lengths at 9,5 cm.
Saw every piece in a 60° angle.

Glue the three 19 cm pieces together and saw a 80° angle off at the end of the piece.

 

Step 3: Drilling

Drill a 22 mm hole (5 cm deep) on top of the right-angled side of the 19 cm piece.

Drill a 7 mm hole on top of the 22 mm hole almost all the way through.

Drill a 7 mm hole at the long side 4 cm from the bottom.

Step 4: Gluing

Glue the two 11 cm and the 3 cm pieces together.  
Do this twice, these will be the legs.
Glue the legs to the 19 cm piece.

Glue the two 9,5 cm pieces together.
Do this twice, these will be the arms.
Glue these pieces to the 19 cm piece.

Step 5: Make the Had

Glue the three 9 cm pieces together (side by side).

Use a 90 mm hole saw to saw a circle out.

Drill a 25 mm hole in the middle of the circle 6 mm deep.

I couldn't  use my jig saw to make a circle out of the 3 cm by 3 cm piece, so I drilled a hole in the middle, put a bolt through it and attached it to my drill press. Then I used some rough sand paper to make a circle.

Glue the 2 pieces together.

Cover the top hole with some wood paste.

Step 6: Electronics Part 1

Put the cable of the power supply through the 7 mm hole.

My power supply had a switch so I didn't  need to attached a switch on  the lamp.
 
Solder the LED driver to the cables of the power supply.
This led driver has a bridge rectifier so you don't have to worry about the polarity of the power supply.

 

Step 7: Aluminum Work

Draw a 3 cm by 3 cm square on one side of a the aluminum bar and draw a cross in it

Place the 3w  LED on top of the cross and mark where the bolt holes of the led will be.

Make two more marks where the cables from the led driver will come out.

Drill these marks out using a 2,5 mm drill bit.                         

Bend the aluminum flat bar in a right-angle where the square ends.

Glue the aluminum bar on top off the 22 mm hole using super glue. 
Make sure the wires of the led driver are through the holes.

 

Step 8: Electronics Part 2

Screw the LED to the aluminum, put thermal paste beneath the LED.

Solder the wires of the led driver to the LED.

Make sure the polarity is correct.

 

Step 9: Ping-pong Ball Head

Take a ping-pong ball and cut a hole in it the size of base of  the LED.

Glue the ping-pong ball on top off the LED.

Glue the had on top of the ping-pong ball.

 

Step 10: Finishing

Now that sombrero LED man is watching over her, my little sister isn't scared of the night anymore.

Comments

author
yongeeks (author)2012-12-17

Excellent design. I may well make one. Thank you.

author
Siddharth Jain (author)2012-10-18

That's really cool!!!...
and the pictures too are good!!!
:D

author
neoroman (author)2012-10-17

Very cool design!

author
AndyGadget (author)2012-10-16

 
I really like the clean, simple lines of this.  A very effective design.
You've given the prices buying everything new, but I think most people would have a lot of the parts somewhere around the house already so it would work out a lot cheaper.

author
HHarry (author)AndyGadget2012-10-17

Thanks!
I also had most materials at home. I just wrote the prices to give the readers an indication of how much everything cost new.

author
SIRJAMES09 (author)2012-10-16

I love it!! I can even think of ways to make him/her movable.
TY for sharing such a cool project!

author
HHarry (author)SIRJAMES092012-10-17

Thanks!

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