Another Floor Lamp #8: Connecting Some Dots

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This is part 8 in a 8 part series: Another Floor Lamp

  1. Starting Small
...
  1. Shaping the Base
  2. Connecting Some Dots

The staves required a dowel hole on the bottom to align with the corresponding holes in the base.   These will not be glued joints.  Instead, I'll use some brass pins (adding a little weight at base level) to align the pieces, which will ultimately be held in place by the nuts on the threaded lamp pipe.

I picked-up a used Pantorouter a few months back, and haven't had a chance to use it until now.  It was perfect for drilling the holes in the bottom of the stave feet.






With an hour or so of sanding on the staves (and a little refinement of the shape), I was ready to join the staves.   To ensure that the staves were glued together in perfect alignment to each other (so that the lamp would stand vertically), I put a reference mark at the same height on each (at 6"), allowing me to align adjacent staves during glue-up.


I dry fit them together just to confirm the alignment all around.


The top-most triangular core I had cut out of end grain cherry to try to make it as inconspicuous as possible.  It will be glued slightly proud in order to provide a flat surface for the lamp pipe fasteners to press against.  If I were doing this again, I would probably alter the stave curve in that area to allow the core piece to mount flush.  Or maybe just carve out a bit on the stave locally to make a flat.  That didn't occur to me until after the glue-up.


Prepping for glue-up.   I should have grabbed the bottle of TB Extend because the TBIII was starting to tack-up as I was assembling.  It was a mildly stressful glue-up.
I started by gluing the triangular core pieces into one of the staves and making sure they were all packed together and seated evenly.  This was the only


Once the core was glued-in, I applied glue to both mating surfaces and pressed-on the 2nd stave, ensuring proper alignment of the reference marks (on the underside in this pic, so not visible).


The 3rd stave went the same way, and then I was frantically trying to clamp things up.  I thought I could get away with using plastic stretch wrap to clamp the staves together.   Unfortunately, the tacking TB III needed more persuasion, so I used a series of squeeze clamps, trying to balance the pressure on adjacent staves to keep them properly aligned and pressed against the core.  I was sweating bullets here, but it worked out fine.  The holes in the stave feet aligned with the pins in the base, so that was a good sign.


Next, I'll finalize the details for the lamp hardware.
More great stuff. 

For future reference, I use these elastic moving bands for odd shapes that are difficult to clamp.  Just cut them to open.  By stretching as you wind them around your workpiece they apply even pressure.  I've used stretch wrap too but when I need more clamping pressure these are my go to clamps.  I usually just use spring clamps to hold the ends but wrapping the end over itself adds some insurance.   

--Nathan, TX. Hire the lazy man. He may not do as much work but that's because he will find a better way.

I just look at the pictures and that's fascinating enough.

The DeWALT clamps still look new and seem to have been purchased for this purpose.

https://dutchypatterns.com/

Nathan - That is an excellent tip!  Those bands would have been perfect.  I'll need to get some of them.  Thanks!

Dutchy - The clamps aren't brand new, but I did get them sometime this past year.   Obviously, they haven't properly been beat-up yet.  🤣
I just noticed that they are not currently available on Amazon but they have other brands that should work.  

--Nathan, TX. Hire the lazy man. He may not do as much work but that's because he will find a better way.

Just reading about it was stressful. 😀  It looks great, and kudos for taking photos during a tricky glue up.