Oak floor lamp with stained glass shade -Build thread

Frank Pellow

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This is a project that I started earlier in the year and put aside for a while. Now, I am starting again and plan to complete the lamp and give it to Margaret (my wife) for Christmas.

In this post I will describe the work that I didon the project last spring.

I spent a couple of months searching the internet for designs of arts and crafts lamps. Finally, in April, I found a design that I like in a book I spotted at Lee Valley. The book is entitled ‘Boxes, Clocks, Lamps & Small Projects and it is published by Woodworker’s Journal. Here is a picture of a Prairie Style table lamp made from quarter sawn oak with opaque glass from Kokomo Glass of Michigan (who made the glass used by Gustav Stickely).

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I believe that I can extend the design to make a floor lamp for our living room.

The real trick to making this lamp is the many shop-made jigs employed in making the frame for the lampshade. I spent a day and a halfall working on these jigs and used them to make a prototype half-frame out of pine.

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Actually, this is my second prototype and it is a little too big.

Here is the tablesaw jig used to make the mortises and tenons at the 55 degree frame ends:

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I took a stained glass course at for 8 evenings at a stained glass store in downtown Toronto and, at the store, I spotted some glass (also made by Kokomo) that will work for the lamp and will fit in with the colours in our living room. Here is a mock-up of the design that I think I will use:

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I think that it is a good compromise between the “glass only” design that I started with and the more complicated “vertical herringbone strip down the middle” design that my stained glass instructor Caroline suggested. I hope that the lamp itself, will be a “work of art” and that this will compliment but not overwhelm the woodwork.

So, I built a real panel:

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I do like it and expect that I will do something quite close to this for the real lamp, but I want to show the design to some folks and I want to think about it some more. I do have time, because I will be building the lamp as a present for Margaret next Christmas and I will build the real frame before making the glass panels to fit into it. There are three things I want to think about changing:

1.Is the fact that one can see the light-bulb through the dark blue glass going to be a problem?

2.Should the four light blue and amber panels form a continuum, as they do in the mock-up. Or can they be a contrast as in the prototype

3.Should the proportions be changed or, perhaps, should the design itself be changed?
 
Here is an extract from my weekly journal written in late May:

Ive talked to several people about the glass for the lamp and everyone likes the glass exactly as I have done it. I did make one slight enhancement and that was to apply copper patina to the solder. Here is a photo taken after the copper patina has been applied:

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I have made a small start on cutting the quarter-sawn white oak lamp-shade frames. I have just enough wood for the lamp-shade frames but must purchase more for the lamp itself.
 
You can add me to the list of "everyone."

The glass looks especially beautiful with the light on. 
 
What a great project!  Thanks for sharing. 

I really enjoy these project threads - such a nice contrast to the threads whining about minor flaws in the tools.

By the way, I really like the contrasting colors of the glass.
 
Thanks Vindingo, Sal, and Jesse.

Yesterday, I got back to this project (after setting it aside for 5 months). I cut the rest of the glass needed for the shade and wrapped the necessary edges with copper foil.

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In about 10 minutes, I will be driving up to a saw mill (Century Mill Lumber)   in order to purchase enough quarter-sawn white oak to finish the job.  I also need to find a hardware store that carries the hardware used in a floor lamp 

 
Excellent project Frank.  Anxious to see the build process.

Curious.  How do you apply a copper patina to the solder?

Thanks for sharing!

neil
 
Frank,

You never cease to impress with the quality of your work and your unselfishness in sharing the details of your build with the the rest of us mere mortals.

Neill
 
neilc said:
Excellent project Frank.  Anxious to see the build process.

Curious.  How do you apply a copper patina to the solder?

Thanks for sharing!

neil
Thanks Neil.

Applying the patina couldn't be easier.  I bought a bottle of liquid that turns the solder colour from silver to copper.  I brushed it onto the solder with a fine paint brush, let it sit for about 10 minutes , then wiped off the residue with a soft cloth.
 
Weekly Update as of Nov 13:

I did make a little bit of progress this week. But, not a lot of progress because I am waiting for this 6/4 quarter sawn oak to acclimatize to my woodworking shed:

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The progress that I made was to solder together the pieces of the glass and to put a copper frame around the assemblies:

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I could have done more but I got off on a tangent this week on a a seperate stained glass project that involves no woodworking at all. I spent between 40 and 50 hours working on this dragonfly:

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When I started learning how to do stained glass work about a year ago, it was done stricktly so that I could "jazz up" some of my woodworking projects but, much to my surprise , I find that I like the stained glass work at least as much as woodworking.
 
I am getting back to this thread after a goof and a recovery from that goof both documented in the thread:
http://festoolownersgroup.com/member-projects/seeking-feedback-and-suggestions-in-order-to-deal-with-a-big-goof-that-i-just-ma/

The frame was assembled by gluing one corner at a time, clamping each joint until the glue dried, then moving on to the next corner:

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The frame was screwed together as well:

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The grooves were filled with walnut wedges cut with 59 degree angles.  I designed a jig to cut the wedges:  

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After letting the glue dry on a wedge, it was trimmed at the top using a fine-toothed hand saw:

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I hope that it will look like I planned the lampshade frame this way.  I will put a bit of walnut in other places on the lamp in order to help make it seem that this was planned.        

The lampshade  is now assembled temporarily but I need to take the glass out in order apply a finish.  I have not yet decided which finish to use.  The plane in the book call to fume the oak, but I am certainly not going to that.  I decided to apply a black patina to the solder and to the frame (in case any of it shows), but the patina that I have would not colour the copper frame around some of the panes.  I solved this by melting a very thin layer of solder over the copper, than applying the patina to that layer.

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Each pane of glass is held in with a narrow strips of screwed to the top and the bottom of the frame:

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Thus, the glass will be easy to remove if necessary.

Here is how the lampshade looks right now:

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I am still working on the top piece (to say nothing about the rest of the lamp).
 
Frank Pellow said:
.....I could have done more but I got off on a tangent this week on a a seperate stained glass project that involves no woodworking at all. I spent between 40 and 50 hours working on this dragonfly:

When I started learning how to do stained glass work about a year ago, it was done stricktly so that I could "jazz up" some of my woodworking projects but, much to my surprise , I find that I like the stained glass work at least as much as woodworking.

Nice work on the dragonfly. [thumbs up]  I'm going to give you the highest compliment, your work with stained glass has inspired me to give this hobby a try.  Now, if I can only find the time.....
 
Brice Burrell said:
Frank Pellow said:
.....I could have done more but I got off on a tangent this week on a a seperate stained glass project that involves no woodworking at all. I spent between 40 and 50 hours working on this dragonfly:

When I started learning how to do stained glass work about a year ago, it was done stricktly so that I could "jazz up" some of my woodworking projects but, much to my surprise , I find that I like the stained glass work at least as much as woodworking.

Nice work on the dragonfly. [thumbs up]  I'm going to give you the highest compliment, your work with stained glass has inspired me to give this hobby a try.  Now, if I can only find the time.....

Hey Brice, I hope that you enjoy working with stained glass as much as I do. 

But, since you are not yet retired, I hope that you do not find it eating into your woodworking the way that I do.
 
December 25th Update:

Well, I didn't get the lamp completed in time for Christmas. I did complete the lampshade and that is what Margaret received as one of her gifts on Christmas morning:

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Picking up since the last last update of this thread, here are the steps that were taken to complete the lampshade:

Four slots for ventilation were inserted into the top piece. I made the slots by drilling holes at the ends, cutting the sides with a jig saw, then cleaning up the slots with a file:

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The top was then glued in place. After the glue dried, the top and the joints were sanded and rounded using 80 grit paper using a Festool Rotex 150 sander.

Then, the whole frame was sanded in stages using 120, 150, 1870, 220, 320 paper with a Festool Duplex linear sander as well as hand sanded with Festool Granat 120, 180, and 320 foam backed pads:

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Finally, one coat of polymerized tung oil sealer and two coats of tung oil were applied leaving a day between each application.
 
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