How to Make a Clamp-on Work Light

Making a clamp on work light is a simple project that will likely result in a good deal of usage. Frequently, stationary lighting or even lamps do not shed enough light or light than can be directed on an existing area. Having a clamp on work lamp give you flexibility and the lighting needed for detailed work. By scrounging for materials around your home and workshop, you can usually create a custom made clamp on work light that will serve you for years. It may not look like much, but it will serve your purposes.

Step 1 - Remove the Base

An old desk lamp is really the best lamp to use for this project. They have small heads, and frequently are easily disassembled. A really great lamp to use is one which has flexible metal tubing connecting the base and the head of the lamp. You will want to remove the base of the lamp, preferably without cutting any wires. If it is not possible to remove the base without cutting the wires, go ahead and cut them to get the base off.You may want to mark the correct position of the cord by drawing arrows in between the cut so you know what wires match up for later.

Step 2 - Ready the Clamp

Put some thought into how you want to be able to position the lamp, where you will most likely be using the lamp, and how much space do you want between the light it's self and the clamp. There is a wide array of clamps available on the market, and many will achieve different results. Do you want one that can be operated with only one hand? Once you know what kind of clamp you want you will need to identify how to fasten the light to the clamp. How the the lamp is fastened to the clamp will depend largely on the different types of materials used. Fasteners such as brackets and screws can be used with metal, or different types of epoxy can be used for plastics. You may want to bore a hole out of one side of the clamp to thread the wiring through.

Step 3 - Affix the Lamp

Affix the lamp to the clamp using either fasteners or epoxy. Allow any epoxy time to set before doing anything else with the work light. 

Step 4 - Repair the Wiring

If you did have to cut the wiring for the lamp, you will need to reconnect it to the remaining portion of the cord. Using a utility knife, carefully cut away enough of the plastic around the power cord to get the the wires inside. Once you get to the wires, separate them, taking care not to damage either of the wires. Separate approximately three to four inches on either side of the cut power cord. identify the corresponding wires and twist them together. Wrap securely each individual set of wires so that no metal is exposed, then wrap them both together to blend them into the rest of the cord.