Base for Bemko's Honeycomb Lamp Shade by blacklabel775

Last crawled date: 3 years, 1 month ago

Designed a base for the Honeycomb Lamp Shade by Bemko (https://www.thingiverse.com/thing:4807723).
This is designed to use a Sonoff Mini, an ESP8266-based WiFi Relay, to control the lamp remotely over MQTT of HTTP, but can also be toggled manually via a momentary switch installed through the wall of the base. I flashed the Sonoff Mini w/ Tasmota firmware (https://tasmota.github.io/docs/) (https://acoptex.com/wp/basics-project-109e/), but it could be used with the standard Sonoff Firmware and their eWeLink app, ESP Home, or other ESP8266 projects or custom firmware. The design is made for an E12 bulb socket, but the "Bulb Holder Mount.stl" part could be easily modified in modeling software or simply by drilling new holes to line up with a bulb socket of your choosing. I am considering using an E12 smart bulb to add dimming and color/colortemp control, and would re-configure the sonoff to send commands to the smart bulb rather than toggling the relay that cuts power to the bulb.
Parts List (Amazon Affiliate Links):
The Dimensions of the base were made for the following parts and so are known to fit. Similar products may also work without modification to the design.
Bemko's Honeycomb Lamp Shade (https://www.thingiverse.com/thing:4807723)
Sonoff Mini V2 (V1 should fit fine as well) (https://www.amazon.com/gp/product/B0829V6JKG?ie=UTF8&psc=1&linkCode=sl1&tag=stephenmetzge-20&linkId=4c204c66ebd72829a982d0f811a88ca8&language=en_US&ref_=as_li_ss_tl)
Momentary Push Button Switch (https://www.amazon.com/gp/product/B0829V6JKG?ie=UTF8&psc=1&linkCode=sl1&tag=stephenmetzge-20&linkId=4c204c66ebd72829a982d0f811a88ca8&language=en_US&ref_=as_li_ss_tl)
E12 Mini Bulb (Candelabra Bulb) Holder Socket (https://www.amazon.com/gp/product/B0829V6JKG?ie=UTF8&psc=1&linkCode=sl1&tag=stephenmetzge-20&linkId=4c204c66ebd72829a982d0f811a88ca8&language=en_US&ref_=as_li_ss_tl)
18 AWG, 2 Conductor (18/2) Power Cable (5.5 mm outer diameter) (https://www.amazon.com/gp/product/B0829V6JKG?ie=UTF8&psc=1&linkCode=sl1&tag=stephenmetzge-20&linkId=4c204c66ebd72829a982d0f811a88ca8&language=en_US&ref_=as_li_ss_tl)
Replacement Power Plug (https://www.amazon.com/gp/product/B0829V6JKG?ie=UTF8&psc=1&linkCode=sl1&tag=stephenmetzge-20&linkId=4c204c66ebd72829a982d0f811a88ca8&language=en_US&ref_=as_li_ss_tl)
22 AWG Wire
E12 LED Bulb (https://www.amazon.com/gp/product/B0829V6JKG?ie=UTF8&psc=1&linkCode=sl1&tag=stephenmetzge-20&linkId=4c204c66ebd72829a982d0f811a88ca8&language=en_US&ref_=as_li_ss_tl)
2 x M3 x 6mm counter sunk head screws
2 x M3 x 16mm socket head screws
2 x M3 Nuts
The threads on the base and retaining nut are a nice snug fit coming off of my modified and tuned up Ender 3. If you are having trouble getting the nut to thread on, let me know and I can try to upload a version with more clearance.
The part "Plug Spacer.stl" was made to close the gap between the replacement socket plug and the 18 AWG wire.
The Sonoff Mini is a very snug fit. I printed this in PETG and was able to get it in place with some firm pressure that caused some temporary deformation of the outer shell. You should still be able to get it pushed in if printed in a more brittle material, like PLA, but be careful not to snap the shell.
You definitely wont be able to wire up to Sonoff Mini first, and then install. It's a pretty tight fit when everything is wired up. I recommend the following order for assembly:
1) Fit the sonoff mini into the inner core through the opening in the front of the base.
2) Feed the 18 AWG (18/2) wire in through the port on the back, wrap around the side of the inner core (not through the inner core) and pull towards the front, and wire into the L-in and N-in terminals of Sonoff Mini. Pull extra slack out through the port on the back, leaving enough so that there is no strain on the connections to the Sonoff Mini terminals. Use a zie-tie as a strain-relief device around the wire on the inside well of the outer shell, You should be able to pull on the cable with moderate force without putting strain on the connection. Cut off as much or as little cable running out the back of the base as needed to reach an outlet where you intend to have the lamp.
3) Put the part "Plug Spacer.stl" onto the end of the cord running out the back, and pull through so that you have enough wire to install the replacement power plug. Remove the cover from the plug, connect wires to the terminals, slide the cover back on and then slide the spacer up into the case.
4) Feed some more 18 AWG down though the center of the inner core and out the side opposite of there the first cable is tucked, pull towards the front and connect to the L-out and N-out terminals of the Sonoff Mini. Pull extra slack out though the top of the inner core, leaving enough so that there is no strain on the connections to the Sonoff Mini terminals. Leave yourself 4-6 inches of slack above the top of the inner core, and cut off excess wire.
5) Connect the 4-6 inches of 22 AWG (22/2) to the terminals of the momentary switch, feed the wires and the switch into the port on the front of the base. Screw on the retaining nut that came with switch to fit the switch snugly to the outer shell of the base. Connect the wires from the switch to the S1 and S2 terminals of the Sonoff Mini. Tuck any excess wire in, making sure not to put any strain on the connections.
6) Make sure all the terminal screws on the Sonoff Mini are tightened up and, inspect the wiring. It is a tight fit and there are mains voltages involved. I am not liable for any damage or injury.
7) Place the honeycomb lamp shade over the base. This should cover most of the wires, only the wire coming from the L-out and N-out terminals of the Sonoff Mini will be coming up through the inner core. Screw the part "Retaining Nut.stl" onto the threads at the top of the inner core and tighten down to attach the shade to the base.
8) Attach the bulb socket to the part "Bulb Holder Mount.stl" using two M3 x 16 mm socket head screws and M3 nuts.
9) Connect the wires coming up through the inner core (from L-out and N-out of the Sonoff Mini) to the screw terminals of the bulb socket. (This is where having some extra slack pays off.)
10) Attach the Bulb Holder to the Retaining Nut using two M3 x 6 mm counter sunk head screws. (Helps to have a long allen wrench.)
11) Screw in the E12 LED bulb.
Supports are only needed for the part "Base.stl".
I designed this in Fusion360 and have included the .f3d file and a .obj file if you need to modify. This could be used without the Sonoff Mini as a non-smart lamp, using a dry contact relay instead of the Sonoff Mini, or some kind of different switch capable of handling 120VAC could be used.