This desk lamp is made with a bent pvc pipe, walnut for the base and the top, lexan for the insert and LEDs for lights! I really wanted to create something a little different, and to use pvc in an unusual way.
Step 1: Bending the PVC
The first part of this build was really the pvc arm. So just creating a jig for bending the arm. Now to actually bend the pvc I'm using the hot sand technique (you can find out more details in the video above.)
Step 2: Cutting the Walnut
For the base and the top we're using some really beautiful walnut.
Because this piece was so small I utilized my planner as a jointer by hot gluing it to a flat piece of plywood and running it through on both sides.
Then just cutting both the top and the base to a round shape and sanding smooth.
Step 3: Cutting the Walnut Top
Here I am using a fly cutter to mark out the location and depth of the Lexan insert for the inside of the top piece of the lamp. Then using the hole saw to mark the depth of the smaller inner dimension that will hold the lights. Then the idea was to carve out the inner section, so just eating that away with a Forstner bit. And then cleaning that up using this hand router, which is such a cool tool.
Step 4: Preparing the Lexan
Next up the lexan, using the fly cutter again to fully cut out the insert, and then sanding that to get more of a diffused look. So the led strip will fit on the inside of the wood, and that way you won't be able to see the individual lights.
Step 5: Fitting the Pipe
Next, drilling a hole in the base for the pvc and testing out the concept.
Step 6: Painting the PVC
To create a cool look, I really wanted a color that kind of pops, so spraying this here with a bright, glossy red, and it needed a couple of coats. It was easier to spray the pvc once it was in the base, so first taping up the base so it wouldn't get red.
Step 7: Gluing the Light Panel In
Next soldering the wires to the strip, and using a 12 volt LED strip here. Turns out it needed a little more glue than just the sticky back, hot glue works great for this.
And the lexan fits perfectly inside.
To cover the edge we cut up a piece of plastic and spray painted that red as well and then attached everything with epoxy.
Step 8: Connecting the Electronics
Now for the base here, putting a switch in. And just carving out some space on the underside. And this hole here is for the barrel plug. Then just connecting everything underneath - so the switch, and the wire coming in from the pipe, and the barrel plug.
Step 9: Gluing Everything Together!
Using epoxy again to secure the pipe to the foot and this stool here was a pretty perfect height to use for support as it was drying.
Step 10: Transition
To create a nicer transition between the pipe and the wood I'm cutting a bigger piece of PVC on the bandsaw. Then using hot glue to secure to the wood, and also adding some hot glue to fill in the gap. Then taping and spraying with the same red paint.
Step 11: Finishing Touches
Finally cutting a piece of leather to attach to the bottom with hot glue, and finishing the wood with shellac.
Step 12: Conclusion - Watch the Video!
For a more in-depth look and to see the final result, make sure to check out the video!