Picking up where I left off in the last installment, I was not happy with the protruding top part of the triangular core. It was just sticking out too much. With a check ring in place (the thing that conceals the end of the brass sleeve that will be installed), it was very visible below the ring. I had even pared-back the tips, but I wasn't happy with the look.
I decided to carefully grind it down using a rotary tool. I used a squeeze clamp on each leg, and clamped each of those clamps to the MFT. That held the assembly pretty securely.
I probably took an hour with different attachments to blend in that top core pieces. I felt like I was a lamp dentist. Luckily, there was minimal collateral damage. Nothing some sandpaper won't take care of.
With the 3/4" brass sleeve set in place for a test fit, I wasn't too crazy about its proportions. It looked too thick. I'll mull over my options, but for now I'll continue as planned.
I purchased a 36" length of all-thread lamp pipe for the project, which would need to be cut down a bit. I assembled the full length pipe in the lamp so that I could mark the required length. Here's the underside. With the driver pocket hollowed out to account for the reduced thickness of the base, I exposed two of the holes that accommodate the brass pins. The two pins will need about 1/8" trimmed-off to account for their shallower holes.
The pipe is held securely to the top of the base with a check ring, lock washer, and nut.
The pipe extends above the small lampshade shelves and then transitions to a cutaway sleeve nut, which is where the wires from the base will exit. The small brace shown here will eventually be anchored to the shelves with 1/8" brass pins. The brace is primarily to keep the lamp pipe centered. However, it could also be used to slightly spread the staves or pull them together, depending on the placement of the holes on the shelves. The only reason artificially flexing the staves would be necessary is if the lampshade ends up being too loose or too tight against the stand-offs at the top of the staves. For this reason, I'm waiting to drill the mounting holes on the staves until after the shade is complete. I know I could build-in some adjustability to the bracket itself, but that seemed like overkill for an adjustment that would be made once.
Here, the lamp pipe has been trimmed to length, and the sleeve nut installed. Another section of lamp pipe continues above to support the LED assembly. The lower LED channel hub will rest on top of the knurled nut, which will allow me to fine tune the height of the LEDs once I see how they appear behind the lampshade.
Up until now, I just had all the LED pigtails wire-nutted together. This was a good time to clean up the LED wiring and install the DC barrel connector in the lower channel hub. In hindsight, I should have chained jumpers between adjacent LED strips to reduce the wiring bulk. But, since it all tucks in behind the channels, it doesn't really matter. Except in my head.
The female connector is accessible between two of the channels. The male connector will be installed on the wires coming up from the lamp base.
Now that the wiring path is all worked out, I'm going to switch to a different product. The narrow lamp all-thread has the appropriate proportions for the staves, but it looks too utilitarian. I'm going to switch to brass pipe that just has threads at the ends. It's a specialty product, so I had to order it from a lamp supply. I also ordered the appropriate sized die because I know I'll need to tweak the length (and threads) of the new pipes.
While I wait for the new plumbing, I'll tackle the shade. I need to go pick out some fabric this week.
Nice work with the brass! Looks like an excellent transition.
I know you are planning to replace the lamp tubing with brass, but one thing I'd suggest are those plastic caps that thread over the end (rod protrudes maybe 1/4" from the top of the nut). These keep the wires from chafing on the tubes ID edge.
It's amazing all the parts you can find for lamps!
Your Dremel surgery was well worth it. That juncture looks much better now.
I think you made the right call with the slimmer, unthreaded brass tube.
That cutaway sleeve nut... did you make the cutout yourself, or can you actually buy them like that?
I also think you made the right call on not adding a spreader mechanism where the stave protrusions meet the brace. From one programming nerd to another, that would definitely be a YAGNI feature. (For non-nerds, that stands for You Aren't Gonna Need It. Programmers are bad about coding provisions for things that are extremely unlikely to occur, and this principle is a reminder for them to stay aware of that tendency.)
I was happy to find those cut-away couplers! I think the cast/machined versions are made specifically for gas to electric wire fixture conversions, but perfect for continuing the post up higher while allowing "escape" holes for wire at various levels.
They are called a "hickey"
I've only ever ordered parts from https://grandbrass.com Fun looking through all the gizmos which can be useful for many non-lamp needs.
Good work tidying up a narrow spot. Places where visual lines meet deserve the most attention.
I am starting to see that I could perhaps use elements of this project myself and wonder: Would it in any way be possible to have the wire run inside one of the legs?
"The good chair is a task one is never completely done with" Hans Wegner
It is always interesting seeing specialty hardware. I’ve never built a lamp and had never heard or thought about cutaway couplers or hickeys.
Kaerlighedsbamsen, I’ve wondered about this too… a channel routed on the underside of one of the feet, threaded inserts on the contact points, and turning the brass locator pins into structural bolts (one being hollow for the wiring). It’s fun thinking up new ways to make Ross contemplate extra work. 😀
Thanks, Pottz. Don't we all get to the point of "that's good enough"? Who can claim true perfection? Maybe it's just that some realize the futility of it sooner and get back to enjoying their life while others toil-on longer before reaching the same conclusion as their wiser brethren.
I know you are planning to replace the lamp tubing with brass, but one thing I'd suggest are those plastic caps that thread over the end (rod protrudes maybe 1/4" from the top of the nut). These keep the wires from chafing on the tubes ID edge.
It's amazing all the parts you can find for lamps!
Thanks, Splinter. Yes, I do have some of those plastic caps that I intend to install during final assembly. Better safe than sorry. Only 24DC will be going through the pipe, but I don't want to risk damaging the driver by a short.
Your Dremel surgery was well worth it. That juncture looks much better now.
I think you made the right call with the slimmer, unthreaded brass tube.
That cutaway sleeve nut... did you make the cutout yourself, or can you actually buy them like that?
I also think you made the right call on not adding a spreader mechanism where the stave protrusions meet the brace. From one programming nerd to another, that would definitely be a YAGNI feature. (For non-nerds, that stands for You Aren't Gonna Need It. Programmers are bad about coding provisions for things that are extremely unlikely to occur, and this principle is a reminder for them to stay aware of that tendency.)
Thanks, Ron, I'm enjoying the challenges of this project. I did not make those cutaway nuts. I got mine on Amazon: link.
Another one from the programmer's phrasebook is, "we're not trying to boil the ocean." I lean reductionist, trying to "keep things simple, as simple as possible, but no simpler." 😃
SplinterGroup commented about 3 hours ago new I was happy to find those cut-away couplers! I think the cast/machined versions are made specifically for gas to electric wire fixture conversions, but perfect for continuing the post up higher while allowing "escape" holes for wire at various levels.
They are called a "hickey"
I've only ever ordered parts from https://grandbrass.com Fun looking through all the gizmos which can be useful for many non-lamp needs.
I just ordered my new brass pipes from grandbrass. My previous order was from mylampparts.com. Many of those bits I will no longer need for this project since switching to the thinner pipe. I'll just need to figure out another lamp to use them on.
I am starting to see that I could perhaps use elements of this project myself and wonder: Would it in any way be possible to have the wire run inside one of the legs?
Thanks, Ty. I bet you could do that! It may require increasing the cross section of the staves to compensate for the loss of material in the one that's been hollowed. But how great would it be to do away with the center pipe?! Please get busy on this project! 🤣
Kaerlighedsbamsen, I’ve wondered about this too… a channel routed on the underside of one of the feet, threaded inserts on the contact points, and turning the brass locator pins into structural bolts (one being hollow for the wiring). It’s fun thinking up new ways to make Ross contemplate extra work. 😀
Yes, you guys are tormenting me! I'm going to try not to think about the hollow leg approach.
Ross Leidy commented about 2 hours ago Thanks, Ty. I bet you could do that! It may require increasing the cross section of the staves to compensate for the loss of material in the one that's been hollowed. But how great would it be to do away with the center pipe?! Please get busy on this project! 🤣
A 24v wire is fairly thin, lets say it would take 12 mm^2, that should be possible to get strong enough, going with straight grained wood. Going all-in, the use of epoxy around the wire could even add structual stability. Hmm, getting ideas here...
"The good chair is a task one is never completely done with" Hans Wegner
Ron Stewart commented about 5 hours ago Kaerlighedsbamsen, I’ve wondered about this too… a channel routed on the underside of one of the feet, threaded inserts on the contact points, and turning the brass locator pins into structural bolts (one being hollow for the wiring). It’s fun thinking up new ways to make Ross contemplate extra work. 😀
Ron, I feel we have a theme going here. Lets see how far we can take it!
"The good chair is a task one is never completely done with" Hans Wegner
Go for it, Ty! I would hesitate to bed the wire in epoxy just because it would prevent replacement of the wire in the future. You could make a narrow surface slot a decorative element of the stave, tuck the wire in, and hold it captive with some type of backer strip that's press fit into the slot (like a fine rubber cord that provides a pinstripe. If the all staves have the "decorative" strip for consistency, you could split the wire and run a single conductor up two staves to reduce the required slot depth.
Looking back at your earlier posts, I see that you drilled 3/8” holes in the staves’ feet. That seems big enough to hold a threaded insert (which specific size, I’m not sure). Then you can run bolts up through the base into the inserts. I’d want clamp scraps on either side of the stave feet to make sure they didn’t split as the insert went in.
Doing that doesn’t eliminate the short section of tubing from the base to the lower intersection of the three staves. Could you add another recess for a hidden nut at the bottom of the intersection point? Then your brass tube would be secured by nuts on both side. The lower nut would be in the staves instead of inside the base,
If that could work, you just need a way to rub the wiring to the lower pipe opening. I wonder if you can buy a hollow nipple small enough to act as a bolt for the stave closest to your driver. That would give you a wiring path from the driver into the foot of the stave. Then you could cut a channel on the underside of that stave to hide the wire. You could secure the wire with hot glue so it’s not permanently attached.
I don’t know if that would work. Even if it did, it would require significant effort (and risk to the staves you carefully shaped). It would also require a round plug for the hole in the center of the base, but it would be in the shadow from the legs, and I doubt anyone would see it.
If it were me, I’d probably just leave it as-is. The original light has a tube there too. If you ever build another one, you could consider a design that eliminates the bottom post.
Ron - I appreciate the mental energy you've applied to the alternate wiring problem. I love this brainstorming. As far as this specific project, I'm going to stick to my current plan to use the smaller diameter central smooth lamp pipe. It's just too risky to try to cut a slot in a stave (or two) now that they're joined together in order to route a hidden wire. However, I find this discussion useful to consider as a different approach for a future project.
Prior to boring the holes in the bottom of the staves, I flipped them over (held together with the rubber bands) and set the assembly upside down on the floor to verify the hole spacing. I stepped back to look at the inverted lamp - it looked like a different lamp I needed to build. 🤣
I just flipped the photo in your introduction upside down, and it does look nice that way—a bit more of a traditional tripod floor lamp look, but more elegant. You definitely wouldn’t want a center tube all the way to the base in that design.