Hi,
Determined to complete this first coach lamp I was in the workshop for 9 o'clock this morning. The threaded rod which secured the top sections had snapped upon removal and was now too short so just another job to take more time; I chucked a length of round bar stock in the Lorch lathe and trued the end then drilled axially at 5mm tapping size; I seldom use tapping size charts; it's easier and quicker to have a nut and select a twist drill bit which is a nice sliding fit. With the hole bored a short length was cut from the bar end and this in turn was tapped at 5mm.
The original rod had a coarse thread and I needed to retain this as it matched the thread in the top ball so I cut the rod using a hacksaw then ran a die down creating a 5mm thread to match the new coupling; the end of a 5mm rod was then run down with the die adding the thread; with the three parts assembled and tightened I could then determine the length of rod required and ran the final thread with the die.
I can't believe I've finally completed the first lamp after the many hours of hassle including a cracked rib whilst metal spinning; This lamp isn't a restoration after all it's mostly a brand new lamp and is bigger than the original because the side lens are now secured with lead came offering a much better seal against our dire climate. The new reflectors went in without trouble; taking decent pictures is usually a problem because it's a workshop not a photography studio; I had to keep breaking off all through the project to take the pictures but I always take lots of pictures for future reference. I can now relax and finish the second lamp. When I started my intention was to restore these two lamps keeping them black and gold but the paint refused to play fair so I painted them to colour match the bungalow exterior and now I'm pleased because I think black and gold would be out of place; these should look better once installed. I'd have preferred rubber seals for the side lens but had to settle for lead came. This project has been more punishment than pleasure due to so many things going wrong and having problems getting decent workshop time but I'm as stubborn as they come so it was only a matter of time before I completed the lamp. Once the second lamp is completed I'll not install them until winter is over because the electrical wiring won't be easy; I want to conceal the cable which will be difficult as the lamps are to be mounted on a random stone wall.
Thank you for your time and patience if you've been following this story.
Kind regards, Colin.
Tapping at 5mm.
Running a 5mm thread using a die.
The extended rod; original coarse thread to the right a new 5mm thread to the left to accept a 5mm nut. The central coupling is tapped at 5mm; a lot of extra work but the lamp top ball is tapped with the coarse thread hence the problem.
The top assembly now completed.
The underside of the top assembly showing the new reflector and the nut on the end of the rod.
Front view showing back and bottom reflectors; the four domed nuts are solid brass.
Right hand view showing lens in new lead came.
Left hand view.
The new lamp on the left being quite a bit bigger than the original lamp on the right; I redesigned making the lamp bigger to accommodate the new lead came and now the top assembly can be lifted clear for bulb replacement; the original lamp has for machine screws which have to be removed allowing the entire body of the lamp to be removed for bulb changing; I like to keep things simple. The lead cames still need a bit of tidying but once these lamps are installed I'll be happy to walk away from them.
Determined to complete this first coach lamp I was in the workshop for 9 o'clock this morning. The threaded rod which secured the top sections had snapped upon removal and was now too short so just another job to take more time; I chucked a length of round bar stock in the Lorch lathe and trued the end then drilled axially at 5mm tapping size; I seldom use tapping size charts; it's easier and quicker to have a nut and select a twist drill bit which is a nice sliding fit. With the hole bored a short length was cut from the bar end and this in turn was tapped at 5mm.
The original rod had a coarse thread and I needed to retain this as it matched the thread in the top ball so I cut the rod using a hacksaw then ran a die down creating a 5mm thread to match the new coupling; the end of a 5mm rod was then run down with the die adding the thread; with the three parts assembled and tightened I could then determine the length of rod required and ran the final thread with the die.
I can't believe I've finally completed the first lamp after the many hours of hassle including a cracked rib whilst metal spinning; This lamp isn't a restoration after all it's mostly a brand new lamp and is bigger than the original because the side lens are now secured with lead came offering a much better seal against our dire climate. The new reflectors went in without trouble; taking decent pictures is usually a problem because it's a workshop not a photography studio; I had to keep breaking off all through the project to take the pictures but I always take lots of pictures for future reference. I can now relax and finish the second lamp. When I started my intention was to restore these two lamps keeping them black and gold but the paint refused to play fair so I painted them to colour match the bungalow exterior and now I'm pleased because I think black and gold would be out of place; these should look better once installed. I'd have preferred rubber seals for the side lens but had to settle for lead came. This project has been more punishment than pleasure due to so many things going wrong and having problems getting decent workshop time but I'm as stubborn as they come so it was only a matter of time before I completed the lamp. Once the second lamp is completed I'll not install them until winter is over because the electrical wiring won't be easy; I want to conceal the cable which will be difficult as the lamps are to be mounted on a random stone wall.
Thank you for your time and patience if you've been following this story.
Kind regards, Colin.
Tapping at 5mm.
Running a 5mm thread using a die.
The extended rod; original coarse thread to the right a new 5mm thread to the left to accept a 5mm nut. The central coupling is tapped at 5mm; a lot of extra work but the lamp top ball is tapped with the coarse thread hence the problem.
The top assembly now completed.
The underside of the top assembly showing the new reflector and the nut on the end of the rod.
Front view showing back and bottom reflectors; the four domed nuts are solid brass.
Right hand view showing lens in new lead came.
Left hand view.
The new lamp on the left being quite a bit bigger than the original lamp on the right; I redesigned making the lamp bigger to accommodate the new lead came and now the top assembly can be lifted clear for bulb replacement; the original lamp has for machine screws which have to be removed allowing the entire body of the lamp to be removed for bulb changing; I like to keep things simple. The lead cames still need a bit of tidying but once these lamps are installed I'll be happy to walk away from them.