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.