This instructable will show you how to create the 'Hanger Lamp' I have designed as part of my BA Product Design final project. My project is based on democratising Upcycling by making designs freely available for re-creation by anyone, I chose to do this as I had noticed that although Upcyled designs are made from free and abundant materials the prices being charged for such designs were pricing many out of the market and creating an exclusive style club for the rich. In order to prove my concept I will need other people, across the globe, to recreate this design and post it to me in London to be displayed at my degree show in June. Please visit my blog Design Democracy for more information, designs and news.

Step 1: Tools & Materials

Materials:

1. Drinks can (500ml is best as it long and has a large diameter)
2. Wire coat hanger
3. Length of 2-core wire (2 metres is a good length)
4. Standard Plug
5. Pendant Bulb holder (the type used on ceiling lights)
6. Small energy efficient bulb

Tools:

1. Permanent marker
2. Scissors
3. Wet & Dry abrasive paper (320 grade)
4. 2mm drill bit
5. 30mm hole cutter
6. Hacksaw, Band saw or Stanley knife
7. Mole grips (Vice-grips)
8. Pliers
9. Can cutting template: download from here

Step 2: Print & Cut Template

Print the can template and cut around the bold outer lines.

Step 3: Mark Can for Cutting

Take your template and affix it to the can, then draw around the edge of the template to mark the can. (I usually just wet the paper and dry off the areas of the can immediately surrounding the template, this saves glue and you don't have to wait for it to set!)

Step 4: Drill the Bulb Holder Hole

Remove the template and drill a small hole in the centre of the can's base. For this you will need either a pillar drill or a friend that trusts you enough to hold the can whilst you drill. Once the small pilot hole is drilled it is safe to drill the larger hole to fit the bulb holder. Following the pilot hole use the hole cutter to SLOWLY cut the larger hole.

Step 5: Cut Off the Top

Cut the top of the can off using a hacksaw, Stanley knife or, if you have one, band saw.

Step 6: Cut the Can to Shape the Shade

Using the scissors, cut around the line marked earlier with the template. The corners can be tricky so avoid them in the first cut and remove the bulk first.

Step 7: Clean Up Sharp Edges

Clean up the cut edges of the can using the Wet & Dry paper, you will get a better result if the paper is wet but not soggy. Ensure you remove any burrs (sharp, spiky bits), the best method is to sand parallel to the edge of the metal then lightly sand round each side of the edge at a 45 degree angle. Let the can dry fully before attempting step 11, unless you like to live dangerously of course, I prefer to keep water away from electricity as it really hurts when it goes wrong!

Step 8: Bend the Hanger Into Shape

Bend the hanger into shape, for best results follow this order:

1. Bend the hook into a smaller circle around the bulb holder. This is easiest using the mole grips and pliers
2. Bend the base of the hanger in the middle to about 90 degrees, the end result will be less than 90 as it will spring back but this is desired
3. Bend the base of the hook (just below the twist) away from the apex of the bend made before

Step 9: Attache Bulb Holder to Hanger

Remove the top of the bulb holder (domed part) and push the thread through the hanger's hook and replace the top. Form a loop in the wire behind the holder and press into the slot in the hanger beneath the twist. Attach the bulb, place the lamp on the table and adjust the bend below the twist until it stands on its own

Step 10: Attach Shade

Remove the bulb, unscrew the bottom of the bulb holder (cone shaped part) and push the exposed thread through the hole in the base of the can, replace the bottom of the bulb holder and bulb.

Step 11: Finished!

Now that you have completed your lamp, why not make another and send one to me, for the fantastic opportunity to have one of your own creations displayed alongside my original at two design shows in June. The first will be at my degree show at the Truman Brewery and the second at New Designers, both in central London! For details please visit my Design Democracy Blog.

Thanks for reading and enjoy creating, remixing and tweaking the hanger lamp!