Adjustable Work Light Arm | I Like To Make Stuff

Summary

In this video, Bob demonstrates how to create a custom adjustable work light. After months of unused tools, Bob designs a track system to hang the light from the ceiling, allowing it to be moved easily across the workspace. Using aluminum tubing, 3D printed parts, and a bike cable mechanism, Bob builds an arm with multiple joints that can be adjusted with one hand. The project also includes integrating a camera light with a mounting system, making it both functional and versatile. Despite a few challenges along the way, the project proves to be a great first step toward improving his workshop lighting setup.

Takeaways

• 😀 The project involves creating an adjustable work light to improve visibility in a shop area, particularly above a lathe.
• 😀 The design includes a track system that can be mounted under the joists of the ceiling, allowing the light to move around the shop.
• 😀 The adjustable arm of the light will have multiple joints, including a top rotation joint, an elbow joint, and a bottom joint that holds the light.
• 😀 The light will be controlled with one hand using a lever that loosens and locks all the joints, allowing easy adjustment and positioning.
• 😀 The design makes use of a bike cable system to tension and lock the joints in place, which was modeled and tested using Fusion 360 and 3D printing.
• 😀 To reduce friction in the bike cable joints, paste wax is used on the printed parts to allow smooth movement when not under tension.
• 😀 The project involves adapting a hand strengthener for use as the tensioning mechanism for the bike cable, offering a simple way to control the light's positioning.
• 😀 The light mount is designed to accommodate a quarter 20 bolt, which is a common fixture for lights and camera equipment, allowing easy attachment of the light.
• 😀 The cable for controlling the tension runs through a PTFE tube to prevent wear and friction as it moves inside the metal pipe.
• 😀 After some initial challenges with the design (including a breakage), improvements were made, such as reinforcing the mechanism with aluminum to handle the spring tension.

Q & A

What is the primary goal of the project in the video?

The primary goal is to build an adjustable work light that can be moved around the workshop, allowing precise positioning of light above the lathe and other work areas.

Why was aluminum extrusion chosen for the ceiling track?

Aluminum extrusion was chosen because it has slots on all four sides, which allows for easy installation of wheels to create a trolley system that can move back and forth across the ceiling.

What material is used for the arm sections, and why was it selected?

Aluminum tubing, specifically a closet pole, was used for the arm sections because it is lightweight, rigid enough to support the light, and easy to work with.

How does the bike cable mechanism work in the project?

The bike cable runs through 3D printed parts, allowing tension to be applied or released, locking the joints into place. A hand-controlled lever tightens or loosens the cable to adjust the position of the joints.

What is the role of the hand strengthener in the project?

The hand strengthener is used to control the tension of the bike cable. By squeezing the handle, the cable tension is released, allowing the arm to move freely, and when the handle is released, the cable re-tensions to lock the joints in place.

What problem did the creator encounter with the 3D printed joints?

The creator found that the 3D printed joints had high friction, making it difficult for them to turn freely. To resolve this, paste wax was applied to reduce friction and allow smoother movement when not under tension.

What was the issue with the wooden mount for the strengthener, and how was it resolved?

The wooden mount broke under the tension of the spring. Instead of rebuilding the entire mechanism, a new insert was created from aluminum to securely hold the spring mechanism in place.

What is the function of the PTFE tubing in the project?

The PTFE tubing is used to guide the cable smoothly through the arm without causing friction, as it moves inside the metal pipe, helping the cable run freely and preventing damage to the wire.

How is the light mounted to the arm?

The light is mounted to the arm using a quarter 20 bolt, which is a common fixture for lights and cameras. A ball joint allows the light to be adjusted easily to the desired angle.

What improvements does the creator plan to make in the future?

The creator plans to improve the geometry of the joints to better lock them into place, increase the tension on the system for more secure positioning, and strengthen the trolley and track system for better durability.