Mickey Lamp - detailed instructions from CDNcruiser

[CDNCruiser]

I've been getting lots of requests for my instructions, so I thought it might be easier for everyone if I just posted them! Here they are!

How to Make a Mickey Lamp

All the parts you need are available at Home Depot.

Here's a close-up of the globe fitter and the hole saw:

The key parts are:

If you cannot find these items in your local Home Depot, go to the Home Depot web site and search for Product number 100671529 (globe fitter) and 100671507 (12" globe) and 100671525 (6" globe). The URL is: http://www.homedepot.com

Begin with the 12 inch globe. Apply masking tape across the top of the globe along the center line in order to mark the centers for the holes needed to mount the smaller globes. Draw a line at the “top dead center” of the lamp and then measure down 4 inches on each side and make another mark. This will mark the centers for each ear hole, the centers should be 8 inches apart.

Drill a small lead hole for each ear and then use a 3 ¼ inch hole saw to cut the ear holes.

Remove the tape and glue the smaller globes into these holes, clamp until the glue is set.

Attach a standard plug to the globe fitter.

Now you need to attach the globe fitter to the post. I used a 2 inch piece of ABS drain pipe as my post. The mount is simply an ABS connector which joins 2 pieces of ABS pipe. First remove the three clamp screws from the fitter. You are going to replace them with 1” screws.

Now turn the globe fitter over and insert the ABS connector into the hole on the bottom of the globe fitter. It's a very loose fit. Drill small lead holes through the holes where you removed the clamp screws.

Use three 1” screws to attach the connector to the globe fitter. Tighten the screws to centre the connector in the hole and secure it. The globe fitter assembly will now slide on and off the ABS drain pipe which will be your post.

Now drill a ½ inch hole about a foot from the bottom of the ABS pipe and feed the power cord up through the pole. Add male and female plugs to the ends of the cord and you are done.

Plug the fitter into the female receptacle you just added, slide the globe fitter onto your post and install a 25 watt frosted light bulb. Place the globe on the fitter and enjoy your lamp.

You will need to devise a base for the lamp. I used a cast metal base for a patio umbrella (WalMart – about $20.00). You simply use a chisel to knock off the nut which holds the retaining bolt and the ABS post slides over the post on the umbrella base. I secure it with two long bolts and wing nuts. Be sure that your base is heavy enough to prevent your lamp from blowing over. The umbrella base has worked very well for me.

On my last few lamps I have added smaller bulbs to illuminate the ears as well as the larger globe.

Begin with a piece of metal strapping, about 4 inches long. Bend about ¼ inch on each end so that the ends will create a “friction grip” on the flange of the 6” globe which is now visible inside the 12” globe.

Make 2 of these pieces, one for each of Mickey’s ears.

Cut a length of outdoor Christmas lights so that you have 2 socket and enough cord on one end to attach a plug. Use pop-rivets to attach each socket to one of the metal straps you just made. Attach a plug.

Your assembly should look like this.

Here is a detailed look at the light socket riveted to the strap. Note the 90 degree bends in the ends of the strap which provide a “friction grip” on the flanges of Mickey’s ears, inside the larger globe. Bend them to provide a snug fit and just press them on.

ENJOY!
Gary Cruise, Kingston, ON November, 2009

Here is a picture of my finished lamp. You can see how the patio umbrella base looks!

[Thumper_ehhhhh]

Awesome thanks

[gillenkl]

great directions - now DH has no excuse not to make one! Thanks.

[charles.headlee]

I think I've seen some reference to this, but no instructions. Thanksgiving party is tomorrow, so I made a few to hang up.

You need one section of rope light, preferably clear, a piece of stiff solid core wire the same length as the lighted section, and a bunch of small zip ties. I had copper 12-2 romex around, it seemed to work OK.

You will need a circular form for the head and ears. Buckets, trashcans, coffee cans, anything round will work. More at the bottom.

Hang the rope light from one end to allow it to straighten out. Straighten out the copper wire. Zip tie the rope light to the wire, using a zip tie at one foot intervals.

Using a bucket, trash can, or whatever as a form, bend one end of the rope light/wire around the form until you have half a circle. The end of the rope light will be the bottom of the head; where you stopped bending will be the start of the ear.

Reverse the direction you were bending the wire, and using a form half the size of the head, bend a full circle. Secure the ear using a zip tie where it meets the head. Leave the zip tie loose and do not trim the tail.

Reverse the direction you were bending to the original direction, and using the large form, continue with the top portion of the head between the ears.

Reverse the direction you were bending the wire, and using a form half the size of the head, bend another full circle, forming the other ear. Secure the ear using a zip tie where it meets the head. Leave the zip tie loose and do not trim the tail.

Reverse the direction you were bending to the original direction, and using the large form, continue with the remainder of the head. Secure the ends of the rope light by overlapping the ends by about 2 inches, and using 3 zip ties.

Once the shape comes together, tighten and trim the zip ties holding the ears in. I applied 2 more zip ties to each ear.

Rope light length and head/ear size guesstimates:

6 foot rope light - 11 inch diameter head - 5 inch diameter ear
12 foot rope light - 23 inch head - 11 inch ear

I found the bottom of the office trash can I was throwing zip tie tails into to be 11 inches in diameter, and the container the zip ties came out of was just over 5 inches.

The bigger you get, the more rigid the wire needs to be. Circular hoops (I think they're used for cross-stitch?) might work. Stuck at work and can't post pictures now, but I'll try in the future.