Handyman Lamp

Robert Perry turns found objects (treasures) into this distinctive handyman lamp.

That's Clever! : Episode HCLVR-111 -- More Projects »
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Project by Robert Perry.

Robert Perry of South Miami, Fla., loves scouring the streets for junk. In fact, in his workshop he's got a bit of everything, including a kitchen sink! He turns someone else's trash into his own treasure. Lighting fixtures have become his specialty and in this project he's creating a unique lamp out of found objects.

Materials:

8" diameter x 1" high spun aluminum base*
iron weight for base
24" carpenter's level
speed square
wood file
3/8" BX electrical cable and 2 connectors
1/2" wire hardware cloth
safety glasses
2 flashlight battery spring terminals
20-gauge silver craft wire
2" wide steel bar stock
90-degree arm back
miscellaneous nickel-plated nuts, bolts and washers
miscellaneous 1/8 ips steel threaded nipples
sticky back felt for base
18-2 SPT-1 electrical cable
18-gauge THHN electrical cable
crimp wire nuts
push in wire inserts
plastic cord nut bushing
medium base electrical socket
candelabra base electrical socket
candelabra cup
300-watt full range dimmer
1 T10 40-watt clear display light bulb (medium base)
1 7-watt clear night light bulb (candelabra base)
degreaser

Preliminary step:
* Drill one 3/8" hole into the center of the top of the base and one 3/8" hole into the side of the high spun aluminum base. This is a preliminary step.

Steps:

1. Clean all of the found objects with degreaser.

2. Use a wire wheel attachment on a bench grinder to scratch a pattern into the side of the 8-inch aluminum base.

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Figure A
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Figure B
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Figure C
3. Using a 4-1/2-inch electric grinder with a 60-grit flap disk wheel, polish the top of the base, the level, the square and the file down to the bare metal (figure A).

4. When each piece is polished, use a rotary tool to etch patterns onto the inside areas of the carpenter's level (figure B).

5. Cut a 1-3/4" x 5" piece of steel bar stock to be used to attach the level to the base.

  • Drill two 3/8-inch holes in the center of the bar stock: one 2-1/4" from one end and another 1 inch from the same end.
  • Drill two 3/16" holes in the other end of the bar stock: 3/4 inch from that end and 3/8 inch in from the sides (figure C).

6. Using the same grinding method as in step #3 clean the steel bar stock, removing any burrs from the holes.