I kept seeing these every once in a great while. And the thought of making one had always been in the back of my mind until I had made a sign out of rebar. I finally decided to give it a try. I actually had more trouble finding the parts than making the actual build. But that was more-so because I was unfamiliar with the lighting department at Menards.
So this project took me approximately 3 hours total. I posted a video Here's what i used:
- MIG Welder
- Tape Measure
- Bench-top Vise
- 3/16" Galvanized Chain
- Lamp Kit
- 18-2 Wire
- 18-2 Plug
- Lamp Shade
- Lamp Shade Top
- .035 Mild Steel Wire
- 75/25 Shielded Welding Gas
- .045 Cut-Off Wheel
- Sanding Disc
- Flat Black Spray Paint
Step 1: Step 1: Build the Upright
I used 2 angles to make the upright part of the lamp. I placed them on the table in opposites of each other and then placed the chain inside of the gap. This makes the chain perfectly straight and symmetrical. Once the chain was in place I used some c-clamps to hold the inner angle in place. I then pushed the outer angle towards the inner angle in order to "pinch" the chain. Then I added 3 small tacks to the outer angle.
Next I tacked each link of the chain. I decided to make the chain upright about 24 inches. If I were to do it again I would make the chain upright only 16 inches. 24 inches is just too tall in my opinion.
Step 2: Step 2: Making the Stand
For this I'm sort of undecided on which way would be the best but I'll explain what I did. I started off by using a piece of angle and standing it upright. I made sure that it was completely plumb to the table. Then for the radius of the stand I used some pipe I had lying around. This pipe was about 2 inches O.D. and in order for the chain to fit around the pipe in a spiral patter I had to cut the pipe bottom in order for the chain to pass through. I used the pipe to get a nice radial start. Once I wrapped the chain so far around the upright I sort of eye-balled the rest of the spiral.
This worked pretty well, but was very tedious. Next time I think I will incorporate some sort of a jig. I went around the upright a few times until I felt it might be stable enough. Once I reached the end I used a vice grip pliers to grip the end of the chain and used a cutoff wheel to cut the remaining length off.
Step 3: Step 3: Spray Paint / Add Nipple
Next it was time to spray paint. I used Flat Black Rust-O-Leum. Being that I used galvanized chain, this took forever. If I were to do this again, I would not buy galvanized chain because the paint really takes a long time to dry to it.
I then cut down the nipple that came in the lamp kit from the hardware store. All this does is makes the height of the shade and light lower.
Then I clamped the upright of the lamp into the vice and cut out the top just big enough to fit the nipple into. Once I had a grove that fit I slid the nipple into the chain and welded it up.
Step 4: Step 4: Wiring
The lamp kit that I bought came with white wire. I wanted black so I was forced to buy 250 feet of 18-2 wire. So for this I had to unspool about 7 feel of wiring. I intertwined the wire with the links going up to the nipple and then fed the wire through the nipple leaving about 8 inches to work with. Then I measured out 5 feet for the plug and cut the wire off.
The plug I bought was something I'd never seen before. This plug requires no stripping of the romex. All you do is simply slide the wire into the plug and clamp the plug down tight. The little teeth in the plug bite into the wire and that's what make the connection. Very simple!
Step 5: Step 5: Wire the Bulb
I shortened the length of the wire sticking out of the nipple. I added the lamp frame and then I had to strip the wiring. There is no set positive or negative on lighting so either or works. I attached one end to the positive and on end to the negative. I Screwed everything together via the instructions of the lighting kit and added the lamp shade with the bulb already inserted.
I actually had to purchase a nut for the lamp shade and the only color it came in was gold. So I also spray painted this black.
Step 6: Step 6: Enjoy Your Lamp
Now everything should be done. I did have to add some touchup paint to certain parts where the wiring went through.
I hope everyone enjoyed this simple DIY. I also have more DIY videos on my YouTube channel here: https://www.youtube.com/adamfleisch
Thanks for looking!!!