Edison Lamp Station

IMG_0981

My initial idea for a lamp included a light switch, a rubber mat to rest your phone on, a metal post for sunglasses, and a pocketed area for change.

Once I started drafting this idea in Vectorworks, and became aware of the size limitations of the 4-Axis, I realized I needed to rework my idea. I knew I wanted something functional for my bedside table, and I wanted to incorporate my skill builder into my final. (For the skill builder I made a small charging dock for an iPhone.)

Vectorworks prototypes:

Screen Shot 2018-04-27 at 11.26.02

 

Screen Shot 2018-04-27 at 11.12.24

Screen Shot 2018-04-27 at 11.06.23

Screen Shot 2018-04-27 at 11.04.09

Screen Shot 2018-04-26 at 17.27.50

Screen Shot 2018-04-26 at 17.02.49

2018-04-27 17.40.02

Once the cherry wood arrived in the mail it became easier to see the dimensions of everything I wanted to mill.

2018-04-29 10.12.42

Because I wanted to maximize the amount of wood I could use I needed to add tabs in Vectorworks to allow the machine to take off the minimal amount on the front and back. This also prompted me to create a third roughing and finishing tool path to ensure the front and back would be milled.

2018-04-29 11.51.52

Unfortunately, the drill bit was not as long as I needed it to be and at one point the callet, collet, caullet however you spell that, ran into the chuck. Oops!

2018-04-29 13.32.00

After restarting the machine due to that error, I was pleased to find I could restart the job without losing all my axies! I edited the tool paths to not mill on either side of the piece.

2018-04-29 14.03.23

Thankfully, the bit was just long enough to be able to mill down to the center on each side.

2018-04-29 15.37.05

Once the 4-Axis started milling the back I saw that the bit wasn’t in fact long enough make the hole for the charger.

2018-04-29 15.42.04

I was a little baffled as to why the machine left such rough lines on the front near the back, but I thought the final tool path would correct that.

2018-04-29 16.12.39

It didn’t unfortunately.

2018-04-29 16.17.44

It left some pretty nasty grooves on the top.

2018-04-29 16.29.12

I thought that maybe if I ran the last finishing step one more time it would get rid of the grooves on the surface.

2018-04-29 16.29.23

So I deleted all the other paths and highlighted the top of the surface where I wanted the machine to mill.

2018-04-29 17.04.07

After milling air for half an hour it finally started to smooth out where I wanted it to.

2018-04-29 17.43.44

But to my dismay, it didn’t smooth it all that much.

2018-04-29 17.43.48

After taking it off the 4-Axis and cutting off the extra wood on the sides using the bandsaw, I was left with some sanding to do. But first I wanted to drill a hole where the bit didn’t go through.

2018-04-29 17.54.12

Hastily, and after 7 hours milling, I slightly damaged the wood around the hole which was frustrating.

2018-04-29 18.03.22

I tried the drill press but it didn’t do any good, so I started filing the area down to make the hole big enough to fit a charger cable.

2018-04-30 16.36.32

Then I got to sanding the sides using a miter guide which made it easy to create an even surface area.

2018-04-30 16.38.16

The finished result looked great!

2018-05-01 14.33.03

Then it was time to discuss how to fit the lamp parts into everything before I lathed the remaining cherry wood bits.

2018-05-01 14.36.00

Ben suggested making a small lamp post and affixing it on the lathe with the chuck and then using the drill to create a hole large enough to fit the guided nipple post — is that what it’s called?

2018-05-02 09.47.40

The cherry wood pieces.

2018-05-02 10.08.58

The failed drill press attempt.

2018-05-02 10.25.06

The cherry wood prepared for lathing.

2018-05-02 10.36.17

2018-05-02 10.43.20

2018-05-02 10.52.59

I needed to make a .7 diameter, 1/4″ deep part at the bottom of my lamp post in order to securely glue it into the 4-axis part.

2018-05-02 11.17.45

Once I had the correct size for that part I started shaping the rounded wood.

2018-05-02 11.25.01

Using three grits of sandpaper, I sanded it until it was really smooth.

2018-05-02 11.28.13

And used the drill to easily make a centered hole through the middle.

2018-05-02 11.36.44

2018-05-02 11.40.40

After band-sawing off the ends, it was ready to be glued!

2018-05-02 11.55.34

Tightly clamped.

2018-05-02 12.00.19

Now it’s time to wait 8 hours.

2018-05-02 15.31.35

Since I had all this time on my hands to wait, I wanted to utilize one more machine, the Othermill.

2018-05-02 15.50.16

Out of aluminum, I wanted to make a lightning bolt.

2018-05-02 15.53.40

It took me a while to remember that the illustrator file had to be filled in in order to show up in Bantam. While the Othermill was doing it’s job I realized a crucial mistake.

2018-05-02 16.28.13

My charger cable wouldn’t fit!

2018-05-02 16.28.18

So I stared at it for a long time thinking of what I could do to remedy the situation.

2018-05-02 16.47.52

Every now and then glancing over and stopping the milling process to vacuum up the pieces!

2018-05-02 17.06.31

Thankfully Ben had a solution for me. And we carefully drilled a round hole in the bottom so I could thread the cable through.

2018-05-02 17.09.08

The lightning bolt came out nicely, and just required a little scraping off the ends to make it smooth.

2018-05-02 17.23.17

Ben was also kind enough to teach me how to properly wire the lamp so I wouldn’t die turning it on.

Screen Shot 2018-05-02 at 17.35.28

Although the two marked areas in red would be rounded, I think the bolt came out nicely.

Screen Shot 2018-05-02 at 12.46.27

The original Illustrator file without it being properly filled in.

Screen Shot 2018-04-29 at 10.00.30

Screen Shot 2018-04-29 at 09.34.34

Screen Shot 2018-04-28 at 15.38.30

Screen Shot 2018-04-28 at 15.36.52

Screen Shot 2018-04-28 at 15.26.09

I realized something wonky that took me a while to sort out when subtracting pieces from the main block in Vectorworks. I needed to use the arrows to have the part I wanted subtracted to be highlighted in yellow and the rest to be highlighted in red or else everything around it would be subtracted.

Screen Shot 2018-04-28 at 15.26.03

What it shouldn’t look like, but what it defaulted to.

Screen Shot 2018-04-28 at 15.05.10

The error I got when improperly trying to subtract the whole shape from the tiny part.

Screen Shot 2018-04-28 at 15.02.13

2018-05-03 00.03.50

After waxing on the lathe and by hand in the pocketed areas.

2018-05-03 00.03.53

2018-05-03 00.20.08

2018-05-03 11.10.25

Felt on the bottom.

2018-05-03 11.05.29

And it’s done!

Leave a Reply

Your email address will not be published. Required fields are marked *