Industrial Cast Iron Pulley Edison Lamp - Metal & Woodworking How To

In this video I make a pulley styled lamp from an old treadle sewing machine base.

This is a pretty straight forward project. I tried to cover all of the steps to make it achievable for just about anybody.

Step 1: The Video.

Here's the accompanying video for the project.

Step 2: Disassemble the Treadle Base

First I disassembled the old treadle base to get to the middle section and pulley. The side panels of the base were cracked so the casting was no longer good for supporting a table.

Step 3: Remove the Pulley and Arbor

I removed the pulley wheel and extracted the center arbor. Then I looked for a good location for the pulley. Locating it on the center truss portion of the treadle base can be tricky. On this project there was a threaded knob that I worked very well as a mount.

Step 4: Find a Bolt for the Pulley

I found a old bolt in my scrap bin that matched the threads. I had to cut it down with my hacksaw to make it fit.

Step 5: Installing a Bushing

The center arbor location need a bushing. I also found the bushing in one of my parts organizers. The bushing allowed me to mount the pulley firmly.

Step 6: Cut the Cast Iron Truss

I found and marked the appropriate location to cut the truss. I also used my right angle grinder with the DIABLO Round Corner flap disc to reproduce the original profile in the casting.

Step 7: Find the Length of the Wood and Locate the Bolts

I placed the cast pulley assembly on the plank of wood to find the correct locations to cut and drill. I used the original bolts to mount the cast assembly.

Step 8: I Used the Original Bolts

In order to use these tapered bolts I had to countersink the back of the wood plank. I used a 3/4" countersink bit.

Step 9: Cut a Channel for the Cord.

I cut a channel into the back of the plank to make room for the lamp cord.

Step 10:

I used a common keyhole router bit to cut the keyhole mounting locations.

Step 11: Distress the Cut End

The cut end was too new looking. So I distressed it with a rock. I used stain and a black Sharpie marker to match the rest of the plank's surface.

Step 12: Sand and Finish

I lightly sanded the lumber to remove loose wood. I then applied two coats of water based polyurethane (satin) to both sides.

Step 13: Paint and Assemble

I painted the cast iron with satin finish black spray paint. After it dried I began to assemble the lamp.

Step 14: Install the Lamp Cord

I disassembled the lamp cord so I could fish it through the back of the wood. I located it in the middle so it would go up and over the cast pulley.

Step 15: Glue the Lamp Card

I glued the lamp cord in place with a high-temp hot glue gun.

Step 16: Locate and Test the Bulb

I glued the lamp cord so it would come out from the middle of the fixture and go up and over the cast pulley.

Step 17: Finished Project

Thanks for reading. Here is a list of tools and supplies I used.

(affiliate links)

SAWS AND CUTTING:

▶ High-Tension Hacksaw

▶ 80 tooth finish blade

▶ Chop saw

▶ Porter Cable Router

▶ Keyhole Router bit

FILING, SANDING & GRINDING:

▶ ▶ DIABLO Round Corner flap disc

▶ DIABLO 4-1/2 in. Metal Cut-off disc

▶ Milwaukee Cordless 18v Grinder

▶ 10" Disc Sander

▶ SandBlaster

▶ Rock - FREE

HAMMERS AND POUNDING:

▶ Ball Pein Hammer

DRILLS, BITS and DRIVERS:

▶ High-Speed Steel Drill Bits

▶ Milwaukee Drill Combo Kit

▶ Tap and die set

▶ Countersink Drill Bit

▶ Craftsman Screwdriver Set

PENS/PENCILS AND MARKING:

▶ Mechanical Pencil

▶ Silver Sharpie Marker

RULERS AND SQUARES:

▶ Tape measure

▶ Swanson Speed Square

SHEARS, SCISSORS & CUTTERS:

▶ Diagonal-Cutters

▶ Rebar cutter and bender

▶ Titanium Shear

CLAMPING, VISES and GRIPPING:

▶ Bench vise

▶ 6 inch bench vise

▶ Channellock 12-Inch Pliers

WELDING, BRAZING & SOLDERING:

▶ Turbo-Torch

FINISHES, PAINT AND COATINGS

▶ Minwax Polycrylic Satin

▶ Rust-Oleum Satin Black

PARTS AND PIECES

▶ Hanging Light Cord Kit

▶ Edison Light Bulb