Don’t’ have the dxf file? buy the dxf file now click here.
You may need to buy longer bolts if you can’t find the exact lengths outlined above. Trim hardware to length as desired after assembly. Buy matching nuts and plenty of washers for all bolts listed above.
Verify the scale. Depending on your software the dxf file may or may not be the proper scale (especially if you are converting to metric). See the image to the left. The largest part is the ‘main arm’ and should be 18.1925 inches long if you have the drawing scaled correctly (462.09 mm).
The sides are inserted into the switch plate then welded The ‘pin’ is a 1/4 inch bolt or you can use a fancy door hinge pin.
The lever switch uses a common USA Standard wall switch.
The medium size gears (secondary gears) need to ‘freewheel’.
How the gears work: The crank and internal 1 inch gear are welded to an axle bolt. The crank turns the lower internal 1 inch gear which then drives the largest gear.
The large gear and the two small external gears are welded to common axle bolt. The large gear turns the 2 external small gears which mesh with the medium size gears.
The medium gears are NOT welded to an axle and are allowed to “freewheel” on a bolt welded to the man arm.
Weld 3/8 bolt(s) to the inside of the main arm(s). The drive gear will freewheel on this bolt. Use a washer between the main arm and the drive gear. Trim the bolt to length after assembly.
The lamp socket is a common ceramic socket. Remove the set screw.
Stack the round spacer plates and use a short lamp nipple.
Small sections of tubing can replace stacks of washer in these areas
Tubing or washers for spacers.
Trim bolts to lengths as needed.
Small section of tubing or washers
Cut off the head of a bolt and weld it to the crank. We used 2 drawer knobs for the handles.
Flat Parts inventory. 11 ga. and 1/4 inch steel parts.
The above information should be enough to get you started. Study all the photos above and below carefully before beginning. Be advised, we used several laser cut wood spacers in place of stacking washers… simply use a stack of washers in place of any wood spacers you see in the photos.
