Hi everyone, Just joined The Garage Journal today to shed some light on this topic (pun intended).
Anyways, I've read this thread numerous times and no one ever said they tried to make these gooseneck stems. Well I just did!
*see attached photos*
No on to how I did it.
First off, in looking out there no one shows how to make these stems or what to make them out of so I started to look at local stores (I live in Eau Claire WI - the home of Menards). I found the same lights that have been talked about previously on this thread but everyone just gave into the straight tube stem.
I will admit a lot of Menards stuff is questionable on quality (kind of between Harbor Tool and Northern tool) but these lights from Patriot Lighting (Model Number: BL14CW) appear to be a pretty good deal at $24.97. The shade is good size, but not completely smooth - can see ribs from being spun, the stem mount and wall mounts are simple and sound - the stem mount looks to be cast and polished, and the light socket is actually ceramic with a 300 watt rating.
Straight stems may work for some people but not me, I'm determined and stubborn, when I have a vision, it's gonna happen and a little tube is not going to get in my way!!
So after I got the 3 light fixtures (for the shade, wiring and wall mount) I also picked up 3 pieces of 1/2" X 48" threaded conduit @ ~$2.50 apiece (fits perfectly into the shade and wall mount threaded attachments) and a 3/4" ideal brand conduit/pipe bender (~$44). All in the electrical department and costing about $150 total.
Once I had my materials I set out to get my shape. Taking a 4' length of string, I laid out my shape using the bender as my guide for the radius ~6" centerline radius. I'd like to note that instead of having the light point straight down I wanted it kicked a little toward the building so that it doesn't blind me driving down the driveway. I have access to CAD so I took my rough dimensions and made a template to follow for all of the lights (see attached photo) (using your original string or tracing it onto plywood would work as well). If space is a constraint a 36" length of pipe would work as well.
1. To bend the pipe, mark out the outer straight lengths, for mine it was 9.5" for the shade side and 9" on the wall mount side.
2. Next I found it easiest to bend the gooseneck first so locate the arrow and line it up with mark on the tube. Then bend the pipe to 90 degrees, it's not super easy to bend but it's not hard.
3. Next slide the bender down the pipe along the bend and locate the bender so it is just at the end of the first bend (too far and you will have a flat spot not enough and the bender will slip - error on not far enough). keep bending until you have the desired bend (I had to bend the pipe 150 degrees).
NOTE: make sure to check your part to the template regularly to make sure the bends are the right angle.
4. The small angle is next to bend, in checking your template mark where the bend starts from the big bend side, the other end of the bend should already be marked.
5. The trick to the small bend is that it needs to be bent the opposite direction from the big bend. Make sure the tube is rotated opposite and slide the bender to the mark just made with the short stub being behind the foot on the bender.
NOTE: To do this bend and not mess up the big bend, put the stub on the second step of a set of stairs and stand on the bender. Because it's a short stub your bending you may need to jump in it a little (at 220 lb I had to).
6. Once you have your shape and it matches your template, make sure it is flat by placing it on a table and find the high spots, use your bender to tweak the conduit side to side as needed to make it flat.
Now I know this seems like a lot but I was able to make all 3 stems in about an hour and a half tops and the plus side YOU GET A TOOL OUT OF THE DEAL!!! By making a template you get really good repeatability. I just did these last night so they don't have the cream colored paint yet and they aren't mounted but I will update as I have them done to show how they turn out.
If anyone has questions on how I did this and needs help or if you don't have the confidence to do it let me know and I might be able to whip up some more.