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  #1  
Old 02-06-2021, 01:54 PM
Gareth Davies Gareth Davies is offline
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Default Aluminium Lamp Canopy Repair

I just thought I'd post this up as it's a little job I was recently tasked with. For a few years now I have worked with someone who has a slightly obscure hobby of collecting street lamp fittings and has literally hundreds of them in his collection. I typically make support brackets for him but have carried out repairs to damaged fittings and recreated parts of obsolete lamps. It's a bit of a side job as there is little money to be made at it but he's a nice guy and some of them are fun to do - a bit of a distraction from real work!

His latest piece that needed attention is a 3' diameter spun aluminium canopy that has an opaque bowl shaped lens underneath and a quick release collar to allow the lens to drop down for bulb changes. Unfortunately, the quick release collar had seized so someone had cut a rectangular hole out of the top of the canopy and self tapped/siliconed a galvanised sheet panel over the hole. My customer really wanted this putting back as close to original as possible so I said I'd do what I could.

Yesterday afternoon was free of other work so I cut myself an oversized patch from 2mm 1050 grade sheet and started rolling it both ways to get some crown into it. It just wasn't getting the shape I needed so I put some little walnuts in with a spoon and shot bag and then shrunk the edges on my Lancaster. After only a few minutes I got the profile right where I wanted it. In an ideal world I'd have wheeled the walnuts out but I sold my wheel a few years ago as I was never using it! I figured that as they were so minimal I could planish them out with a slapper when the patch was welded in. The patch was offered on, scribed through then cut and trimmed. It welded in reallly nice with 1100 grade filler rod and then I ground the excess off from both sides and then proceeded to planish. I finished off with a slapper and dolly, sander and DA sander. It's not perfect and may require a bit more work before it goes for powder coating but there's no major sunk in areas or bulges. The crown has stayed in so the spun profile looks continuous so I'm pretty happy with the results.

Here's a few progress photos.

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  #2  
Old 02-06-2021, 01:56 PM
Gareth Davies Gareth Davies is offline
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More photos

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Old 02-06-2021, 02:52 PM
Overkill Overkill is offline
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Default Hobby

Yes, that is an obscure hobby indeed. Great repair.
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Old 02-07-2021, 07:59 AM
metalmarks metalmarks is offline
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Looks good! Do you have a photo of the collection?
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Old 02-07-2021, 03:28 PM
Gareth Davies Gareth Davies is offline
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Quote:
Originally Posted by metalmarks View Post
Looks good! Do you have a photo of the collection?
I donít Iím afraid. He has a website but itís quite hard to navigate and doesnít show things off very well.
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Old 02-13-2021, 06:19 AM
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Gojeep Gojeep is offline
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Nice bit of welding there.
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Old 02-13-2021, 01:43 PM
Gareth Davies Gareth Davies is offline
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Originally Posted by Gojeep View Post
Nice bit of welding there.
Thanks, it flowed quite well considering it was old to new which is where youíd normally expect to have issues. It was fairly well prepped though so that went in its favour. The customer collected it yesterday and was more than pleased with the job so thatís what matters really.
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Old 02-15-2021, 01:14 PM
crystallographic crystallographic is offline
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Quote:
Originally Posted by Gareth Davies View Post
Thanks, it flowed quite well considering it was old to new which is where youíd normally expect to have issues. It was fairly well prepped though so that went in its favour. The customer collected it yesterday and was more than pleased with the job so thatís what matters really.

Excellent.
(hoping you get some repeat business - )
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Old 02-15-2021, 06:58 PM
cliffrod cliffrod is offline
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Very cool- looks great.
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  #10  
Old 02-16-2021, 12:54 PM
Gareth Davies Gareth Davies is offline
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Quote:
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Excellent.
(hoping you get some repeat business - )
Thanks Kent, he’s already planning what to send me next

Quote:
Originally Posted by cliffrod View Post
Very cool- looks great.
Thanks. I think I could’ve done it better if I had an air planisher but building one of those is still on the ‘to do’ list.
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Last edited by Gareth Davies; 02-16-2021 at 12:57 PM.
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