Fusion Projects »

PVC is a very versatile material.

There are hundreds of projects on the web using PVC pipes for fun.

In this instructable I will teach you how to make a lamp diameter approx 360mm (36cm or 14") made almost exclusively with 50 mm (2”) diameter PVC pipe, joined together entirely with PVC pipe glue/cement, recreating and approaching the original 1970 Roger Rougier design. These were as props for Paramount Studios. They have appeared in Star Trek (TV/Movies) as well as in movies such as “Scarface” and most recently in “The Hunger Games” series.

In this case the model is to hang from the ceiling.

You will see that it has a very vintage style.

I'll explain step by step how to make one of your own.

Let's start!

Step 1: Supply and Tools

9 meters PVC pipe Ø50x1.8 mm.
PVC pipe glue/cement.
1 M4 x 70 screw with washer and nut.
Lamp holder and lamp (*) + Cable.

(*) I used an edison screw socket, and a LED lamp. It also depends on the voltage and current of your country. Warm light lamps will cause a more vintage style, while daylight will be a little more modern.

Tools:

Ruler.
Pencil.
Table saw.
Carpenter press.
Joinery clamps.
Sponge sandpaper (superfine, fine and coarse).
Ethyl Alcohol.
Brush.
Clean cloth.
Drill and bit Ø4.5 mm.

Step 2: Design

I used Autodesk fusion360 software to made the design.

I started from a hexagon made up of 37 tubes of Ø50 x 1.8 mm thick.

Then I made a sphere with a diameter of 360 mm whose intersection cuts out the 37 pipes, configuring the rough design of the lamp.

The design provides for an area inside the sphere to place the lamp and allow the light to spread sideways and up and down.

To access the interior through the bottom of the sphere, a group of 7 joined pipes later called "Bottom Pole" can slide smoothly down to allow the hand to reach in and add or change a bulb.

As there is symmetry, the final lamp´s design is made up of 6 types of pipes:

Type 0: Ø50 x 100 mm long - Quantity 2.

Type 1: Ø50 x 100 mm long with 16º angle cutout at the top - Quantity 12.

Type 2: Ø50 x 91 mm long with cutout at the 29º angled end - Quantity 12.

Type 3: Ø50 x 85 mm long with cutout at the 34º angled end - Quantity 12.

Type 4: Ø50 x 259 mm long with cutout at both ends at a 60º angle - Quantity 6.

Type 5: Ø50 x 289 mm long with cutout at both ends at a 49º angle - Quantity 12.

Step 3: Straight Cut Pipes

PVC is a very easy material to cut. In plumbing works, the use of manual cutting tools is very common.

In my case I chose my table saw.

Before cutting, it is necessary to mark with a pencil the dimension of the different pipes (according to the plans) and also indicate the type of pipe (0,1,2,3,4 and 5), information that will be useful when assembling the sphere.

To mark the measurements of the pieces, fix the pipe to a table or workbench with carpenter's press.

When measuring keep in mind the size of the saw to avoid that the size of the pipes is less than what is indicated in the plans.

when cutting it is convenientt use personal protection elements such as glasses, headphones and gloves.

Step 4: Angled Cut Pipes

With the table saw (or other appropriate cutting method), being very careful, you can apply the angled cuts of the pipes type 1,2,3,4 and 5 either by varying the cutting angle of the table saw or also with the rulers with angle guide that bring this type of tools.

Be very careful with the sharp edge of the PVC.

You can avoid injuries by always wearing gloves.

Step 5: Cleaning and Sanding Pipes

This step is rather boring.

But believe me, it is very important for your work to look neat and correct.

It is also an essential condition for the correct gluing of the pipes.

PVC pipes usually come with inscriptions of ink and dirt.

First, spray on ethyl alcohol and wipe each pipe with a clean rag.

Then sand with the help of sanding sponges. First "fine" and then "semi fine".

Apply coarse sandpaper to the edges of the pipes, taking special care with the edge of the PVC.

After sanding, spray ethyl alcohol again and do final cleaning.

Step 6: Construction of the Sphere of Pipes

First of all, I suggest reading the attached sphere assembly sequence (third graph included in this step) to understand the whole process. It is also important to see all the rest of the photos and graphics.

Mounting poles:

First, we will assemble the two poles of the sphere: 2 hexagons with 7 pipes, with a type “0” pipe in the center and 6 type “1” pipes on the perimeter. We will mount the "top pole" and the "bottom pole".

Before gluing, position all the pipes, adjusting their position so that the upper surface is left with a uniform curve of the sphere.

Apply glue for PVC pipes on the area of the pipes where there is contact with the others, with the help of a brush.

Even though the PVC can be glued with any type of adhesive, I suggest doing it with PVC glue used in plumbing to join the pipes with their accessories.

This type of glue is quick drying, so be sure to apply the glue and quickly press the pipes together with joinery clamps to create immediate bond.

In order for the set to stick firmly, it may help to fasten the set with string or a ribbon or an elastic as well.

Intermediate Row Assembly:

Next, we will paste an exterior hexagon containing the previous poles (top pole and bottom pole), made up of 12 pipes: 6 type “2” and 6 type “3”.

As in the previous case, prior to gluing we will position all the pipes, adjusting their individual position so that the upper surface continues with the uniform curve of the sphere.

It may be helpful to use the attached schematic.

For gluing, keep in mind that the upper half of the sphere of the lamp is completely glued (without access), while the lower half of the sphere will be accessed through the piece called "bottom pole".

That is to say that in this case you will only have to glue the 12 pipes (type "2" and type "3" together, without gluing them to the "bottom pole".

Also in this case so that the set sticks firmly, it can help to adjust the set with thread or a ribbon or also an elastic.

Once finished, we will have built two hemispheres. We are near the end of the montage.

Type “5” pipe gluing:

Position six pair of type “5” pipes and glue them together as seen in the photos. You can use joinery clamps to perfect gluing.

Assembly of the total set:

Place the two half spheres supported as indicated in the figure, separated at a distance of approximately 156 mm.

Position a pair of type “5” pipes and glue them as indicated in the photos.

Use joinery clamps for perfect gluing.

Go turning the assembly through the axis of the sphere that crosses the two semi-spheres and glue other pairs of pipes type "5" until completing the six.

Finally position the pipes type "4" in the places and glue them as indicated in the photos.

Use joinery clamps for perfect gluing.

Also rotate the set and paste until you complete the sphere.

Step 7: Final Assembly

Support the sphere with the fixed pole (top pole) facing up and the removable pole (bottom pole) facing down.

With the help of a drill, make two Ø4.5 mm holes and pass M4x70 screw with nut and washer as seen in the photo (first and second photo of this step). This screw is used to hang the lamp to the ceiling.

Attach a cable to a lamp holder and insert it through the upper pipe type "0".

Choose the best height from the floor or from the ceiling to place the spherical tube lamp in your house or in the place you want, depending on the architecture, tables, etc. Connect the wire from the light fixture to the junction box located on the ceiling.

Place the lamp inside the sphere, inserting it through the lower part of the lamp, removing the sliding "bottom pole". Once the lamp is in place, put the sliding bottom pole back in place.

In my case I used an LED lamp (low consumption) with an Edison-type thread.