I started with a smack block of hardwood and drilled a 3mm small pocket on one side.
Then I inserted one washer. Using a 2mm drill bit, I ground a 120 degree point on the shank end. After flipping the bit into my drill press chuck, I pressed the first washer into the bottom of the 3mm hole. This washer got stuck, which is good because each washer after will have a metal surface to conform to.
Insert a washer in the hole and repeat the drill press action to dish the washer.
Next I drilled another 3mm hole next to the first, just shallow enough to hold the washer in the hole. Drill a 1mm hole into the point at the bottom of the new 3mm hole about 2mm deep. Insert a cutoff 1mm diameter shank piece 3mm long into the hole at the bottom. This will keep the tube close to flush with the tube when inserted later
Flip one washer top of dome up. And place it into the hole with the pin.
Set the tube into the hole of the washer, and a tiny bit of flux where they meet. Touch the joint with a tiny drop of solder and the end should be soldered.
Use a 2mm spherical engraving bit to dish the light reflector.
If the tubing fills with solder, use a 0.5mm drill to clear the hole be sure to aim for the center of the tube as it may be off center.
Use a cutoff wheel to cut the tube off about 5 or 6mm behind the reflector. After testing with a 3v battery, insert the magnet wire end of a 0201 pre wired LED into the reflector and pull it through till the LED sits into the reflector. Make sure the LED face is away from the reflector. Add a drop of CA to set the LED in the center.
Next, use a jewelers ring tool to bend the reflector end about 60 down. Don’t do this bend until the LED wires are in the tube first. Test the LED with a 3v battery after bending. Wind the magnet wire to a gentle twisted pair.
Take a round toothpick and chop off one tapered end roughly square to the toothpick. About 3mm from the cut end make a drill point in the center of the toothpick. Use a 1mm drill bit to attach the light arm. Use a scrap piece of 1mm tubing to check fit into the hole. Use the drill bit to enlarge the hole if needed.
Feed the LED wire through the hole in the toothpick, insert the tube into the hole until the tube is flush with the other side of the toothpick. Make sure the light is rotated properly. Bend the magnet wire close to the Toothpick. Add a drop of CA into the tube and hole in the toothpick.
Hold the magnet at the pointed tip of the toothpick, parallel to its centerline. Add CA along the wire.
Finish the pole with your favorite color. I used Sepia color India ink.
I decided to add an angular brace above the light arm. Drill a 0.018 hole 1mm from the top of the pole halfway into the toothpick. I used 0.015” phosphor bronze wire with a 45 degree bend at the end. Insert the bent portion into the hole and mark the wire to be cut at the top of the light arm and snip it off. Insert the wire into the hole and lift the cut end atop the arm. Add a drop of flux and a drop of solder to finish the brace.
I will be painting the arms and braces with Rustoleum galvanized color paint, extracted from the spray can when all seven are complete.
