Introduction: Work Light and Cord Reel From PVC Tubing
I saw this Husky work lamp at Home Depot and really liked the design. Being an avid intructabler (is that a word?), I thought I could improve on it and only spend about half ($35) of what it cost at HD. I wanted to stay away from the tripod legs that are bound to brake off and go with a pedestal design where the base doubled as a cord reel. I like to keep things compact and self contained.
Anywhere I can, I like to design things with multiple uses.
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Step 1: Assemble the Parts
1-piece of 48" x 4" black PVC drain pipe
1-piece of 24" x 3" black PVC drain pipe
2-3" pipe caps
1-4" pipe coupler
2-plastic screw-in lamp bases
2-100 watt fluro bulbs
3' of lamp cord
3" of appliance cord with molded plug
1-2 plug receptacle
1-2 plug receptacle cover
2-pieces of 3/4" x 18" square plywood
Various misc screws
Step 2: Make the Lamp Bases
The idea here is to mount the lamp bases on 3/4" plywood and reduce their circumference to fit inside the 3" tubing. You'll need to be careful and cut a hole on the bottom for the wire connectors and a slot in the edge to slide the connector wire from the other lamp base.
This will only work with plastic bases, you can't cut the ceramic ones.
Also, it's easier if you put solder-less connectors on the ends of the wires for hooking them up.
Step 3: Making the Lamp Holder
The idea here is to cut out some of the tubing to expose the lamps. I cut out about 1/2 of the tubing using my jig saw leaving rounded corners that look pretty good.
Take your time sanding the rough edges with what ever works.
You'll note that this design does not have a lens or cover over the lamps. I thought it would be too much to try and bend clear acrylic to create one so it's open. The bulbs are pretty cool to the touch though.
Note: when you use a jig saw, the plastic will want to close up after you cut it so you may have to go back and make a second cut on the same line.
Next run some aluminum tape inside the back of the lamp holder to 1) reflect the light back out of the holder and 2) cover the lamp wire for the top bulb.
Next mount the lamp bases inside the tube so that about 1" of "base" sticks out of the opening. Slide the other lamp base in the other end over the groove you cut for the wire.
Now cap the ends with the 3" tube caps and screw it to the tube. Countersink the holes and use flat head screws. You should add the loop at the end of one cap prior to mounting to the lamp holder.
Finish off the holder by connecting the positive and negative wires to the appliance cord as shown.
Step 4: Making the Storage Tube and Lamp Holder Support
This step describes the tube that elevates the lamp holder and doubles as a storage tube. Slide the lamp holder into the 4" piece of tube so that it stores the holder and cord. Put a wooden plug in one end about 2" from the end and leave the other end open.
When not in use, this tube stores the lamp holder and when in use and converts to hold the lamp up off the ground mounted in the center of the cord reel.
Step 5: Making the Cord Reel
Here's the final piece. This cord reel doubles as a storage for about 70' of extension cord that can be used by it self or when laid flat on the ground, holds the lamp support in the center of the reel.
The center of this reel is the 4" coupler and the plywood edges of the reel mounts to it from inside the coupler. The lamp support tube fits snugly inside this center.
I mounted a 2 outlet plug to power the lamp holder or maybe a battery charger. Tape over the wiring on the outlet so nothing shorts out.
Step 6: Final Results
Here's the finished product with lamp holder on top of storage tube mounted inside cord reel.
It really does give off plenty of light and is great to put in the corner of your work space.
Please let me know what you think and rate this instructable.
Also check out my YouTube video for more details and visit my YouTube Channel "TheToolManShow".
Thanks for watching.
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