DIY Welding Project: Swinging Light Shop Mount [Guide] | MillerWelds

DIY Welding Project: Swinging Light Shop Mount [Guide]

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Eyesight ever challenged in your shop? Build this adjustable swinging LED shop light to your welding space.
DOWNLOAD PROJECT PLAN

SKILL LEVEL: Beginner

TIME COMMITMENT: 2 hours

Here's what you'll need to get started.

TOOLS AND MATERIALS

Miller® Multimatic® 220 AC/DC multiprocess welder
Drill or drill press
5/16" drill bit
13/32" drill bit

3/32" drill bit

1/2" drill bit or step drill bit  

Bandsaw or cutoff wheel 

C-clamps 

3/8" – 16 UNC tap 

9/16" wrench 

3/4" wrench/socket 
Hammer
Transfer punch
4' LED shop light (chain pull switch attached)
50" of 3/4" square tubing (the length of the square tubing is determined by the length of your shop light)

1-1/2" x 1/8" flat stock

4-1/2" x 1/2" bolt 

6" x 1/2" bolt 

3/8" bolts (2) (used to mount to steel structure) 

Nyloc nuts (3) 

1/2" washers (2) 

123 machinist block or welding square 

.40 stainless safety wire 
 

WARNING: READ AND FOLLOW ALL LABELS AND THE OWNER'S MANUAL.

STEP BY STEP

Welder holding flat stock.

STEP ONE:

Cut your 1-1/2" flat stock to 6" to be used as your wall mounting plate. 

Close-up cutting flat stock.

STEP TWO:

Cut two additional 1-1/2" pieces from your flat stock. Rounding two corners is optional.

Drilling a hole in the two flat stock pieces.

STEP THREE:

Drill a 1/2" hole in the center of the two pieces. The hole should be 3/4" from each side. Debur the bottom if needed.

Drilling a hole on the mounting plate.

STEP FOUR:

On the mounting plate, drill two 13/32" holes 1/2" from each end.

Drilling a hole in the square tubing.

STEP FIVE:

Drill a 1/2" hole 9/16" from each end of the 3/4" square tubing.

Welder tack welding a bolt to square tubing.

STEP SIX:

Set your Multimatic 220 AC/DC to the 14-gauge Auto-Set™ mode. Tack weld the 4-1/2" bolt into one of the holes on the square tubing to create the swing point.

Tip: It helps to grind the plating off the bolt beforehand.

Screwing the nut onto the bolt.

STEP SEVEN:

Grab the other end of the square tubing and place the 6" bolt in the hole and use the nyloc nut. Put the nyloc bolt on the top side to create the handle.

Welder welding two pieces together.

STEP EIGHT:

Weld the 1-1/2" flat stock with the 1/2" holes (from steps 2 and 3) to the mounting plate. One piece should be placed 1-3/4" from one end and the other piece should be welded 1-1/4" from the other end. Weld just the insides of both pieces, setting the Auto-Set to 1/8" on the Multimatic 220 AC/DC, and let it cool before removing clamps to minimize warping.

Drilling a hole into the square tubing.

STEP NINE:

Painting the square tubing is optional. Drill a 3/32" hole in the square tubing above where the chain would've mounted to the light.

Threading stainless safety wire through wall light./ Chain pull switch hanging from the swivel end.

STEP TEN:

Use .40 stainless safety wire and thread it through the light mount, up through the square tubing and back around. Be sure to secure the ends and make sure the chain pull switch is at the swivel end.

Transfer punching a hole into a steel post.

STEP ELEVEN:

For mounting to a steel post, transfer punch the wall-mount hole. Drill with 5/16" drill bit and tap the holes for 3/8" bolt and install the wall mount.

Putting a nut on a bolt.

STEP TWELVE:

Install the light mount by sliding the swivel bolt through the top hole. Run a nyloc nut up the bolt far enough that it won't touch the bottom mount hole. Then add a washer.

Securing the nut to the bolt.

STEP THIRTEEN:

Put the swivel bolt through the bottom hole, add a washer and secure the remaining nyloc nut. To adjust tension, tighten the upper nyloc nut down to the bottom bracket until it touches. Then tighten the bottom nyloc nut to increase the swivel pressure.

About Andy Weyenberg

Andy Weyenberg headshot
Andy Weyenberg began welding at his father’s business a few years before joining the Army. After going to school for Electro-Mechanical, he started working for Miller Electric Mfg. LLC as a technical service rep and training instructor. Andy has built and raced stock cars since he was a teenager — and now builds high-performance street vehicles while also managing the Miller motorsports program.

Get Project Ideas & Plans

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