Repro Tilley Reflectors

As promised, this is a new thread addressing the Tilley Reflector blanks that I can supply. The tooling is made; and I took the first production sample to Newark for member's assessment. It was very well appreciated . It is a close copy of the KL80 reflector, but is also a very close match to most other Tilley models with a 12" reflector. It looks fine on any of the models that had a 12" reflector.



It is spun from 20guage steel and the inner hole diameter can be cut to suit several Tilley models.

KL80 - 108mm centre hole.
EX4 / IL33 / IL47 - 122mm hole.
PL53 - 127mm hole.
X246 models - 141.5mm hole.

It can also be provided with no centre hole cut if you want to fit it to another type of lamp. These will just have the centre marked as a reference point.

The blanks do not come with slots or other mounting holes drilled, but I have taken measurements from several of each type of reflector and can provide a sketch with position and dimension data as a guide to where to cut the necessary slots etc.

I will not be holding stocks of these as there are too many variations, so they will be made to order only. I took lots of orders at Newark, but for those that were not there and want some, you can send me a PM with your "firm order" clearly stating which type you want. They will cost £13.00 each plus P&P which is as yet not determined as I need to source some suitable cartons for shipping. They weigh 500g each. Shipping and packaging charge will be actual cost only. No payment is required until the items are packaged, weighed and ready for shipping.

I will be placing the first production run order on Monday 17th June so please get back to me quickly with your order if you want any. Please include you shipping address and if overseas a contact phone number in case Courier delivery is necessary.

Steve.

 

Just sourced some new packaging boxes 14" Pitza cartons . Also now got a feel for UK postage at least. My-Hermes is the cheapest option, beating RM by a shed-length! First estimate P&P + shipping costs for the UK are:

1 Reflector - £5.00
2 Reflectors - £6.00
3 Reflectors - £7.00
4-5 Reflectors - £8.00
6 Reflectors - £9.00

There are more permutations, but at least this gives a good estimate of shipping costs to start with.

Steve.

 

Just cut the slots in a KL80 blank and thought you might like to know how I did it.

1. I first marked out the slot, taking 1/2 the width of the slot off the total length of the slot. (eg. for the KL80, with 35mm long by 8.5mm wide slots, subtract 4.25mm from 35mm and you get 30.75mm)

2. I used nails hammered into my workbench around the blank to support it while working on it. If you don't fancy nails in your bench, use another wooden base.

3. Making sure that the blank is supported underneath, mark the hole drilling point with a centre-punch.

4. Starting with a small drill, say 2mm, and progressing with several steps of larger drills, work up to the 8.5mm hole.

5. I used a Junior hacksaw, with a very fine tooth to cut down the slots to reach the outer edges of the holes. You could use a very fine Dremmel cutting disc.

6. Using various suitable files I evened up the slots and removed all burrs.

Maybe others will do this a different way, but this worked for me. The hardest part is getting the marking out absolutely right. Remember the old addage "measure twice and cut once". I tend to measure at least 3 times!

The PL53 version is going to be the hardest to do as it has 4 slots. When you get your blanks, don't forget to tell us how you cut your slots and show some pictures please.

Here are some pictures - Regards - Steve.




Continued.

 

Slots pictures continued:



Steve.

 

Nice !
Well done. But can you tell me why the rim, also from the originals, are rolled the wrong way up.
This way dirt, moisture etc. can get "in" the rim.

If rolled inwards this will not happen.

 

I guess it has to do with the way they are made. There is a mould where the steel is spun upon and trying to roll the steel inwards would result in crimping it on the mould.

 

Hi WimVe,

Rolling the rim upwards is easier and keeps the cost down. Also, these are not meant to be exact copies, but a workable, cheap alternative to having no reflector at all. remember, many lamps were sold without reflectors, they were an optional extra, at extra cost. I am trying to provide an inexpensive option for those who would like it. Also, when painted with a good coat of VHT paint, the very slight gap at the rimm will be sealed. The interest is quite astounding so far!

Steve.

 

Hi Steve,

I know your motivation and I admire it. The question was more general.

But cheaper would be a rim a little angled going down for about 5mm. This will stabilize the rim enough to keep it "straight".

Some german reflectors have the rim "a little bit" curled inwards to make it possible to keep a bead skirt in place.

 

Hi Steve

Looks like a winner to me , the Tilley reflctors i used on lamps while i was in the RAF are virtualy identical to the ones your having made & they really look the part 8)

I wonder if they'll fit the Bialaddins too without too much bother , probably just need a few slight mods those old two part ones always used to get bashed about a fair bit , but were good to pack away when on the move

Stu

 

Hi Stu, Yes I believe that the split Bialaddin/Vapalux reflector was a result of military packaging requirements. A Bialaddin reflector is certainly possible if there is enough demand. Good news is: Spinner has the reflector orders and estimates two weeks for delivery. Steve.

 

Excellent. I want one for my TL120 I got at Newark please. Look good chromed. I'm away at mo but can get measured by end of weekend unless that's one you're getting done already.

 

Hi Ross, Got you down for 1 X Tilley X246 reflector at present! I don't know what a Tilley 120 inner hole size is, so let me know what inner hole diameter you need and I can add it to the Spinner's order. Thanks for Newark mate . - Steve.

PS. Looked in the Gallery and the TL120 has a similar gallery to the KL80. If the reflector sits on the gallery, then the KL80 reflector should fit. However, I do not think that the TL120 ever was supplied with a Reflector. Steve.

 

It's the standard gallery. It came with pleated shade but a reflector will be better for camping. My TL120 is the chrome one with anti-bug fittings.

 

If that's the case Ross, a KL80 reflector will do the job. So do you want a X246 and a KL80? No problems, just let mr know what you want. Steve.

 

Thanks. Put me down for a KL80 one as well.

 

Hope you don't mind me chiming in hear but that TL120 you bought Ross, had the later chromed steel gallery. Not owning one myself I don't know if they are the same size as the old brass ones but yours was certainly different looking. There isn't one like your in the gallery but Stephan's lamp in this post has the same one as yours. Might be the same but worth checking.

 

Good point Matt . Best thing is you measure the gallery diameter Ross, or if you can borrow a KL80 reflector, try it on . If you do need an odd size reflector, the Spinner can accomodate . Meanwhile got you down for X246 and KL80. - Steve.

 

Hi Matt !
Ross's lamp is actually a TL120A he brought last week end it takes the 182 glass and has the tabs that fold out from the gallery.
Sadly it was Tilley's last attempt at a table lamp ,the princple or idea was great with removable stem for posting / packing but a not very attractive top half ! with that weird pleted shade.
Ross was taking the lamp and shade camping to southern France in summer so Tess can read a book at night ! maybe he can ditch the shade as it will never last the trip ! and lightly sand blast a 182 glass ! the outer glass shades are a bit of a balancing act so not really an option.
Page 26 of tilley book shows TL120A.

However !! have you considered an X410 reflector ?
This lamp had an optional small reflector that only stuck out from the glass by roughly two inches . That would suit the TL120A very nicely to cut down the glare of the lamp from above and a 182 can be used not sand blasted !

Neil ? can you add the missing pic of what I am going on about to Matt as my computer don't post pics at present !
X410 reflector ?
maybe or should I say neil I'll garenttee you've got one of these smaller reflectors , that will confuse Shed man !
that means another spinning former to make !
Has that confused you matt ?

mick

 

Probably heresy but a Kindle Paperwhite would be a better solution.

Put me down for two, Steve...

 

I thought that it might be the TL120A but didn't want to confuse our poor stovie stepping over to the light side with technicalities, sorry Ross.

Is this the reflector you mean? [url=http://0flo.com/index.php?threads/4274 Difficult to get an original so yes, another little project for Steve after this one. Not sure if the demand would be quite so high. Sounds like David's got a couple though.

 

Mick just sent me this to put up shows the 7inch reflectors for the 410 lamps

pete

 

Shedman is very easily confused . However, if you ask me to consider making a reproduction item; if I can, I will get it made for you . Meanwhile, I will do my very best to help folks to get their lamps complete, and working, even if it is with a reproduction part. Best to all - Steve.

 

Hi !
Yes I know the tank on X410 is smaller than a storm lamp hence smaller reflector but at 7 inches it would reflect alot of light and might look a smart alterative slipped over the pressed steel gallery , just one hole to cut , no slots if Ross was looking for something to go travelling with.

Trying to travel down through France I guess space is a premium so a smaller reflector and a purpose made box for lamp would be a great help ! and when lamp in use it can sit on top of box !

Last time I talked wooden boxes to Ross I really dropped myself in it by making all his shelf units to house his stove collection !

mick

 

& damn fine shelves they are too!

Thanks for the help everyone. I have just measured the gallery & looks like I'll need a 90mm hole. I'm going to double check that again in the morning as it's been a looong day. I'll stick with the 12" diameter for now but will get a 7" one too if Steve gets them made for others. I'm looking to get mine chromed & will likely get the glass frosted as Mick recommends. I think the lamp will look good with frosted glass & chrome reflector. Not original but practical & non-destructive (got a spare glass).

I'm not regreting it but when I bought the TL120A (1973) lamp I was under the impression the pleated shade was simply opened up & plonked on the lamp then folded for transit. In reality you need 5 hands to make it up & once it's made up it's best to leave 'as is'.

@David - Tess & a kindle! Non-starter. I've tried.

 

Ross, Any size hole can be accomodated in the 12" reflector blanks, just let me know what you need. The other option is what Niel McCrae is having, blanks with no hole cut, only the centre marked, and then cut your hole to suit. Let me know by Monday if you can. Meanwhile, you are downfor a KL80 and a X246. Let me know if this is still correct you. I will ask the Spinner about a 7" blank, but will probably need to see one or at least have some measurement and idea of curvature and hole size. Steve.

 

Given the X410s were export models I don't think we'll be seeing one anytime soon, Steve, particularly as the reflectors were optional extras. Having said that, it's amazing what some collectors have got squirrelled away...

For what it's worth, on the X410A the distance from the centre of the hood to the end of the air-tubes is 50mm so to clear them, the centre hole will need to be something in the order of 105mm and perhaps a tad more.

I've no idea of the size of the slots or even why Tilley decided to make them 'T-shaped' on this lamp but not others - perhaps the Yanks wanted the handles to fold down for some reason. Who knows...

Edit - Neil has one, [url=http://0flo.com/index.php?threads/2364

 

If you havnt already Ross, I can frost your globe for ya

 

Thanks for the X410A dimesions Ray. I will wait for Ross to tell me what he wants. If he is not worried about originality of shape, but only wants a functional reflector, I am pretty sure that the Spinner can knock one up maybe using some existing tooling. Steve.

 

I forgot about the 410 reflector. I should have taken that to Newark as well as the others. I guess I can always mail it if you want to measure. ::Neil::

 

Thanks Neil, but I will wait to see if there is any real interest for the 410 reflector. Good to see you and Sylvia made it to Newark for a few hours. take care mate - Steve.