- A mast debited and soldered
- Supports with scrolls
- False airs of gas nozzle
- 1 - Assembly and fixing of the mast
- 2 - Assembly of the volutes of the support
- 3 - Manufacture of lanterns
- The electrical connection to the garden
Christian Judet adorned his garden with a powerful and decorative luminaire, comprising three lanterns supported by an octagonal mast. The whole culminates more than 2.50 m from the ground and does not lack charm!
Retro floor lamps can be found on the Internet and in DIY superstores. But few are as big as Christian Judet's. Inspired by the gas beaks of the late nineteenth centurye century, his creation combines ready-made volutes (Bourguignon) with the octagonal shaft of an old street lamp. This allowed our reader to focus on the manufacture of three lanterns and their assembly on the scrolls arranged at 120° around the mast.
A mast debited and soldered
The barrel of the original lamppost was 11 meters long and was first reduced to its upper part, then re-cut into several sections. The longest (1.80 m) corresponds roughly to its central part, while the shortest (0.70 m) constitutes its base, the intermediate and high parts being suppressed. The difference in diameter between the sections allows to find the aesthetics and the proportions of a pole of retro lamp post. The effect is even accentuated by the octagonal plate interposed between the two sections (two sheets of 150 x 150 x 6 mm welded to one another).
Supports with scrolls
Asymmetrical and terminated by crow's feet, six volutes are assembled in pairs (one large and one small) to form three gallows. They are then gathered around a "crown" formed of three rings Ø 108 surrounding a bar section Ø 20 x 160 mm. This bar is welded in the center of two superimposed platens solid iron Ø 75 x 8 mm, and then welded to the top of the mast.
False airs of gas nozzle
The structure of the lanterns consists of two superimposed frames 290 mm apart (overall height: 320 mm), joined by four 15° inclined posts. Under the lower frame, four full bar spokes 12 x 12 mm curved at 70° meet around a base Ø 80 x 16 mm pierced in the center up to mid-thickness to be able to weld the lantern at the end of the volute corresponding. Glazed on all four sides, the whole, wearing a hat made of four bibs and a pyramidal top, is surmounted by a square chimney that reminds the one of the gas jets.
1 - Assembly and fixing of the mast
Only four of the eleven meters of the barrel of the recovered lamp post are preserved. An intermediate section of 50 cm is cut 70 cm from the lower end. The lower part will then be welded on the high section of 1.80 m.
Two sheets 180 x 180 x 4 mm, welded to one another, serve as mounting plate to the mast. Drilled in the center (Ø 24 mm), the set is also drilled at the corners (Ø 18 mm).
The fixture plate of the lamppost is bolted to a base made from angles falls under which were welded anchors (bent metal rods) which will then be embedded in the foundation concrete.
Cut into the foot of the lamp, an opening of 40 x 150 mm facilitates the electrical connection. It is closed by a screwed plate of 50 x 180 mm sealed with silicone sealant.
2 - Assembly of the volutes of the support
A first pair of scrolls is clamped in position, flat on a flat support. The future cup is then drawn to the ruler and the square at the end of the large volute (lantern side). The operation will be renewed for the other two pairs of volutes.
The first pair, consisting of a small and a large scrolls welded together, serves as template for the following. The three pairs are gathered around a cylindrical spacer (here a tin serves as a template) of the corresponding diameter.
Before welding the support at the top of the mast, the end of the large volutes is shortened and ground to engage under the turntables of the lanterns.
The mast is previously drilled in three points (Ø 10 mm). These holes are used to pass the power cables lanterns, clamped by collars around the mast and glued on the scrolls.
3 - Manufacture of lanterns
Two 20 mm angle frames, one of 350 x 350 and the other of 190 x 190 mm, form the structure of the lantern. Returned to the workbench, the larger of the two receives two of the four uprights (diagonally opposite) held inclined and pointed. He's fooled
Returned to the workbench, the larger of the two frames receives two of the four uprights (diagonally opposite) held inclined and pointed. Then you have to point the small frame then the other two amounts.
Each side of the large frame is pierced with two holes (Ø 4.2 mm), threaded (M5 x 80 mm). This will allow to screw the bibs of the hat, formed of four sheets cut, folded and welded miter.
Returned, the frame of the lantern is centered on the bibs of the hat, turned too. The locations of the eight previously tapped holes are then marked with a pencil.
The triangular sheets forming the top of the hat are held and pointed in pairs. Gathered, pointed and ground, they serve as templates for the following.
Top and bibs are joined by four angles of 20 x 20 mm, and four lugs drilled (Ø 3.3 mm) and threaded (M4 x 70 mm). Each is welded perpendicular to the inside of one of the angles.
The locations of the holes of the legs are reported under the edges of the hat. Marked with a needle punch, they are then drilled (Ø 5.5 mm).
In series, chimneys are drilled on each side of a hole (Ø 16 mm). Three half-holes are drilled down the faces (contiguous) to remove condensation.
To cut the glazing with precision, it is better to cut templates in cardboard of the same thickness, leaving a clearance of 1 to 2 mm.
Glazing is retained at the top by welded legs.
Glazing is fixed at the bottom by screws in stainless steel or brass, screwed into the lower frame. Plastic tube sections serve as dampers.
The electrical connection to the garden
The supply of a 230 V outdoor luminaire is subject to strict requirements stipulated by standard NF C 15 100. First, it is advisable to draw a specific line of 3 x 2.5 mm2 from the distribution board (or a small secondary panel), and to protect it by means of a high sensitivity switch or circuit-breaker (30 mA).
Rigid, the conductors (U 1000 R2V or FR-N 05 VV-U) walk in an orange TPC sheath buried at 80 cm deep (1 m under a driveway). Resting on a bed of sand or loose earth, it is covered with a red warning wire (NF T 54-080).
No splicing is allowed. The sleeve opens into the luminaire where the connection (dominoes) is made, at least 30 cm above the floor. To protect this connection while leaving it accessible, it is recommended to install it inside a 2P + T outlet box for outdoor use.