I'm excited to share the possibilities that can come from simple hand tools!
In this instructable, I'm going to make this awesome lamp. I made this lamp by-hand, without power tools (aside from a drill.) I did it as a challenge. I was glad I took the challenge on, because this was a learning curve for me, as well. It was a very slow and tedious process. If you have power tools and wish to make this lamp, then you'll know which power tools to use.
For viewers with less tools be sure to watch the video to get more information on the build. Find all the material used at the end.
Overview of the lamp
- 9-inch concrete base
- Mahogany wood
- Removable power plug
- ON/OFF power switch
- Adjustable light head
- Removable plexi-glass light cover
Step 1: Making the Form
To make the form, I used a large 9-inch vase. I took a piece of metal flashing, wrapped it around the the vase, and added tape to hold it in place. Then, I placed plastic over the vase to keep the cement mix from making contact with the glass.
Step 2: Mixing the Concrete
Any concrete mix will work for this base. To make this mix, I am going to use a two- to-one ratio (1 cup of cement mix and 2 cups of sand) then add water. I put construction mesh in the mix to strengthen the form.
Vibrate the form to get rid of the air pocket. Let the mix sit for three days. This should be enough time to cure.
Step 3: Wiring the Body of the Lamp
I found these small pieces of mahogany lumber in a nearby dumpster.
All the cuts were made by hand on a miter box. The body of the lamp is made of two 1-inch by 2-inch lumber. The 1 x 2 inch lumber is cut to a 22-degree angle, where the wood meets the concrete base. (See photos for all the measurements.)
Clamp the 2 (1 by 2) together then drill out a hole for the power port and also the power switch. Mark and chisel out a track for the the wire to pass though the middle. Refer to the video for more information on the wiring circuit. Cover the connections using painter's tape. Then, add wood glue and clamps.
Step 4: Making the Light Cover
I used a 1/4 piece of plexiglass, cut it to fit the opening of the, counter sink, the screwed the holes.
Spray the plexiglass from the inside using spry frost. This will help hide the LED light strips. I also sprayed the ends to hide the wires/connections.
Step 5: Installing the Led Strips
Cut each strip to length at the connection point. Peel and stick each strip side-by-side. Solder the strip to each other, and connect all the reds on one end and all the blacks on the opposite end.
Glue and clamp. After the glue is dried, sand all pieces. Use wood filler if needed.
Apply your favorite stain. I didn't stain because I like the color of the lumber. I applied three coats of wipe on poly as a protective layer.
Step 6: Attaching the Base
Drill a hole in the center of the concrete using a masonry bit. Insert the bolt then transfer the angler over to the wood. Drill a hole in the middle of the wood. Since I am using hardwood, the bolt I am using will create threads in the hole. This will be enough to hold. If your using pine, I would suggest using a threaded insert in place.
Step 7: Attaching the Body to the Lamp Head
Attach the two parts, and drill a straight hole through the two. Make sure you have enough wire for the swing of the lamp head. Splice and cover the wire connection. Tie a knot or place a zip tie on the wire so it cannot be pulled out. Attach the light cover.
Step 8: Final Touch
I applied a clear coat to the concrete base. Then, I added some rubber bumper to the bottom to protect any surface it may rest on. The lamp is complete. See below for all the items used in the project.
- LED http://amzn.to/2hHvE6y
- Power Supply http://amzn.to/2gNiG5I
- joint Nut http://amzn.to/2gNiG5I
- Toggle switch http://amzn.to/2gNiG5I
- DC Jack (inlet) http://amzn.to/2gNiG5I
- Wood glue http://amzn.to/2gNiG5I
- Metal flashing http://amzn.to/2gNiG5I
- Painters tape http://amzn.to/2gNiG5I
- Cement and sand mix
- Disconnect connectors http://amzn.to/2gNiG5I
- Frosted Glass http://amzn.to/2gNiG5I
- Black Spray paint http://amzn.to/2gNiG5I
- Spray Lacquer http://amzn.to/2gNiG5I
- Miter box and saw combo http://amzn.to/2hHEcL5
- Clamps http://amzn.to/2gNmsMi
- Chisel http://amzn.to/2hnzHEt
- -Solder kits http://amzn.to/2gNAaPh
- Razor knife http://amzn.to/2hQdjAv
- Wire stripper http://amzn.to/2hnDD7Q
- Volt meter (optional) http://amzn.to/2gNkJXm
- Counter sink bit http://amzn.to/2hHAe53
- Wood drill bit http://amzn.to/2hnDeTh
- Masonry bit http://amzn.to/2gD8iKt
- Tape measure http://amzn.to/2gNnKXS
- Drill http://amzn.to/2hQe9gD