DIY: Safe(er) Cheap Light Fixtures [Picture Heavy]

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Many people use the light fixtures posted in guides such as the Crossfire enclosure. No offense to the creator because he is undoubtedly smarter than me, but using extension cords like that is unsafe.
I have made my own light fixture wiring that is much safer. It is also cheap. Three light fixtures and all the materials cost me $40.82 including tax.

Green = ground
Black = + , hot
white = negative

I am not responsible for any damage or injury from following this guide. This wiring may be safer than the popular methods, but any time electrical work is done there is a change of injury, fire, etc.

Supplies:
1x 25 ft 12awg extension cord from Harbor Freight
http://www.harborfreight.com/25-ft-x-12-gauge-outdoor-extension-cord-41449.html

2x 15amp male 3 prong straight blade plug from Harbor Freight
http://www.harborfreight.com/125-volt-15-amp-male-plug-93686.html
Note: reviews say this will not work with 12 gauge wire, that is incorrect. It will still work, it is just a tight fit

3x Home Depot light fixture and base
Unable to find on website.
Ys0FQqv.jpg


Electrical Tape

Heat Shrink, optional but recommended

Wire nuts or soldering iron, soldering iron recommended

Wire cutters and strippers

Let's get started
1. Measure out 8 feet of cord from the extension cord. I measured from the female end to get the tough part (2 cuts instead of one) out of the way.
IPV1CnQ.jpg


2. Cut at the 8ft mark.
O34vPKM.jpg

If you measured from the female end like me, cut the female end off.
int0x7F.jpg


3. The easiest way to cut the plastic back is by making two cuts across from each other, then cutting the bottom off of each section. After trimming, strip the wire. I like plenty of wire, so I stripped about 1 inch off. Do the same to the other end if you cut the female end off. If you started at the male end, leave the male end on.
jdiJzWC.jpg

z4a2xJl.jpg

dCPn6zA.jpg


4. Screw the light fixture to the base. Make sure the wires run through. I almost forgot, so here is me trying to in the middle of the project.
VpUy1W1.jpg


5. This screw is your ground.
WxfqyL0.jpg

Take it out
4XfaTgZ.jpg

And wrap it clockwise in your ground wire from the extension cord.
Be sure to leave some threads at the end visible so it is easy to screw back in.
IGWF2fe.jpg

Screw it back in, making sure the wire is still wrapped snug.
s7xPdxa.jpg


6a. These instructions are for soldering or could be used if you plan to only use heat shrink (skip to 6c if so). If you want to use wire nuts, that will not be covered. Twist the two black wires together
K2OAl1m.jpg

6b. Solder them together.
L4HobK0.jpg

6c. Slide heat shrink that is just barely big enough to cover the wires over them.
gqJcLJZ.jpg

6d. Trim and heat the heatshrink.
Br4DURo.jpg


7. Repeat step 6 for the white wire.

8. Take apart the male plug.
Begin with these screws
LaidHrZ.jpg

And then take out these ones.
8aqa8Zb.jpg

6BOIe4o.jpg


9. Stick your extension cord through just like this. Also, make sure there is plenty of plastic removed. When you put it back together, it will not close on the entire cord but it will close on the 3 wires with the orange extension cord plastic removed from that section.
ohOqBPa.jpg


10. Unscrew the ground screw most of the way. It still needs to be threaded slightly, though. It will be green colored. if not green colored, it will be the one in the bottom center. Opposite it is the long round "probe" that sticks into the ground plug of your outlet.
lLQb9Tx.jpg


11. This is the easiest way to insert the wire. I struggled to figure it out with the ground, but got it with the black. You separate the wire into two parts and put one part on either side of the screw, then screw it in.
pcGaRqz.jpg


12. Do the same for the black and white wires. On mine, the white wire was marked with a "w" on the plug end.
Here, you can see it better.
gB3yg4H.jpg


13. Use the electrical tape to tape up any copper wire you see. Be sure no piece of wire is touching another piece.
WvnAxVC.jpg


14. Reassemble the yellow plug. It will be a tight squeeze. in order for it to close properly, no orange plastic can be inside the plug or the clamp that closes it.

15. Light bulb goes in first, safety first.
t1vjh4P.jpg


16. Plug her in
vWnc79w.jpg


17. Let there be light!
tre7g9r.jpg
 
ToothlessC":1ak0ocp5 said:
Many people use the light fixtures posted in guides such as the Crossfire enclosure. No offense to the creator because he is undoubtedly smarter than me, but using extension cords like that is unsafe.
I have made my own light fixture wiring that is much safer. It is also cheap. Three light fixtures and all the materials cost me $40.82 including tax.

Green = ground
Black = + , hot
white = negative

I am not responsible for any damage or injury from following this guide. This wiring may be safer than the popular methods, but any time electrical work is done there is a change of injury, fire, etc.

Supplies:
1x 25 ft 12awg extension cord from Harbor Freight
http://www.harborfreight.com/25-ft-x-12-gauge-outdoor-extension-cord-41449.html

2x 15amp male 3 prong straight blade plug from Harbor Freight
http://www.harborfreight.com/125-volt-15-amp-male-plug-93686.html
Note: reviews say this will not work with 12 gauge wire, that is incorrect. It will still work, it is just a tight fit

3x Home Depot light fixture and base
Unable to find on website.
Ys0FQqv.jpg


Electrical Tape

Heat Shrink, optional but recommended

Wire nuts or soldering iron, soldering iron recommended

Wire cutters and strippers

Let's get started
1. Measure out 8 feet of cord from the extension cord. I measured from the female end to get the tough part (2 cuts instead of one) out of the way.
IPV1CnQ.jpg


2. Cut at the 8ft mark.
O34vPKM.jpg

If you measured from the female end like me, cut the female end off.
int0x7F.jpg


3. The easiest way to cut the plastic back is by making two cuts across from each other, then cutting the bottom off of each section. After trimming, strip the wire. I like plenty of wire, so I stripped about 1 inch off. Do the same to the other end if you cut the female end off. If you started at the male end, leave the male end on.
jdiJzWC.jpg

z4a2xJl.jpg

dCPn6zA.jpg


4. Screw the light fixture to the base. Make sure the wires run through. I almost forgot, so here is me trying to in the middle of the project.
VpUy1W1.jpg


5. This screw is your ground.
WxfqyL0.jpg

Take it out
4XfaTgZ.jpg

And wrap it clockwise in your ground wire from the extension cord.
Be sure to leave some threads at the end visible so it is easy to screw back in.
IGWF2fe.jpg

Screw it back in, making sure the wire is still wrapped snug.
s7xPdxa.jpg


6a. These instructions are for soldering or could be used if you plan to only use heat shrink (skip to 6c if so). If you want to use wire nuts, that will not be covered. Twist the two black wires together
K2OAl1m.jpg

6b. Solder them together.
L4HobK0.jpg

6c. Slide heat shrink that is just barely big enough to cover the wires over them.
gqJcLJZ.jpg

6d. Trim and heat the heatshrink.
Br4DURo.jpg


7. Repeat step 6 for the white wire.

8. Take apart the male plug.
Begin with these screws
LaidHrZ.jpg

And then take out these ones.
8aqa8Zb.jpg

6BOIe4o.jpg


9. Stick your extension cord through just like this. Also, make sure there is plenty of plastic removed. When you put it back together, it will not close on the entire cord but it will close on the 3 wires with the orange extension cord plastic removed from that section.
ohOqBPa.jpg


10. Unscrew the ground screw most of the way. It still needs to be threaded slightly, though. It will be green colored. if not green colored, it will be the one in the bottom center. Opposite it is the long round "probe" that sticks into the ground plug of your outlet.
lLQb9Tx.jpg


11. This is the easiest way to insert the wire. I struggled to figure it out with the ground, but got it with the black. You separate the wire into two parts and put one part on either side of the screw, then screw it in.
pcGaRqz.jpg


12. Do the same for the black and white wires. On mine, the white wire was marked with a "w" on the plug end.
Here, you can see it better.
gB3yg4H.jpg


13. Use the electrical tape to tape up any copper wire you see. Be sure no piece of wire is touching another piece.
WvnAxVC.jpg


14. Reassemble the yellow plug. It will be a tight squeeze. in order for it to close properly, no orange plastic can be inside the plug or the clamp that closes it.

15. Light bulb goes in first, safety first.
t1vjh4P.jpg


16. Plug her in
vWnc79w.jpg


17. Let there be light!
tre7g9r.jpg


Firstly Bravo! It bugs me everytime I look at crossfire enclosure, such an fire hazard with no grounding
But I do have to correct something within your guide that bothers me..

12. Do the same for the black and white wires. On mine, the white wire was marked with a "w" on the plug end.
Here, you can see it better.
gB3yg4H.jpg

The way your wires contact is in its self an hazard, they should be twisted tightly together and then pushed into the contacts(dont have an picture currently but will upload one soon). You should never wire something up in that manner. Your next step is alright but you should never have to do that if you wired it in a neat manner in the first place.
 
ToothlessC":2wp7rha1 said:
12. Do the same for the black and white wires. On mine, the white wire was marked with a "w" on the plug end.
Here, you can see it better.
gB3yg4H.jpg


13. Use the electrical tape to tape up any copper wire you see. Be sure no piece of wire is touching another piece.
WvnAxVC.jpg

Proper way to wire into a plug is having plastic insulator all the way to the screwing clamp, and not to have a birds nest of wires sticking everywhere
M5Sjr0i.jpg

qYNayAo.jpg


Also in my pictures you should never cut excessive outer insulation, only cut as much as you need an alittle extra to give more ease
The clamp marks on the cord, are due to it being an outdoor plug in, but having an water proofing connection is good in any sceneraio
 
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