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

696

26

4

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

About: Hi, I'm a Maker of things. I'm interested in almost anything Science, Technology, Engineering, Art, and Math.

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

3 People Made This Project!

Recommendations

  • Tiny Home Contest

    Tiny Home Contest
  • Creative Misuse Contest

    Creative Misuse Contest
  • Fix It! Contest

    Fix It! Contest

4 Discussions

Wow that's really impressive. Well documented too. I know it's a late comment but this was the first time I viewed it.

1 reply

Awesome. I have an old sewing machine with parts just like this. Now I just need to convince my wife to let me take them apart.

1 reply