I was recently commissioned by a local brewery(Escape Brewing) to design and produce some wall lighting for their new expansion. I decided to go with an industrial theme with some medieval styling cues.
This was hands down one of my personal favorite builds as it required so many disciplines: metal fabrication, woodworking, blacksmithing, and some simple electrical work.
Since I didn't want to overwhelm you all with too many images, some of the steps in the video aren't included in the images. If you are curious about the Wine barrel chandeliers I made for the same brewery or any of my other work, please feel free to check out & subscribe to my DIY YouTube channel ZH Fabrications.
Step 1: Cutting the Frame
The first step was to cut out the frame. The frame is made of 1"x1"x1/8" angle iron.
I used a DeWalt cold saw for this. I truly believe this to be the most deafening tool one can own!
Step 2: Welding the Frame
With the pieces for the frame cut, the next step was to weld the frame together. I'm using a Lincoln 140C MIG welder.
Step 3: De-burring the Socket Housings
After cutting out some 2x3 square tubing(Cold saw again), I'm de-burring the holes I drilled which will later accept the bulb.
Step 4: Constructing the Panel
The next step was to cut out the panel, which will set inside the frame. I'm cutting a piece of 2x12 Southern Yellow Pine.
Step 5: Chamfering the Edges
With the panels cut, I'm chamfering the edges so there will be a visible & rustic joint when the panels are glued together--without this the panel would resemble laminated plywood.
Step 6: Fire!
I also torched the chamfer to heighten the contrast once the piece is assembled and stained.
Step 7: Mock-up
With the panel glued up, and routed for the socket frame--this is the mockup assembly.
I used a DeWalt plunge router on the panel to accept the socket frame
Step 8: Staining & Finishing
Step 9: Final Mock-up
Getting closer, this is the final mock-up with the blackened metal patina, and stained & clear coated panels.
Step 10: Forging Nails
For the final medieval touch, I really wanted to use some hand forged nails--so I made a bunch of them! This was a lot of work, but it was also a fun process, and beating red hot steel always makes you feel awesome.
Step 11: Nails!
Step 12: Wire It Up!
Wiring up & installing the sockets.
Step 13: It's Alive!
Step 14: Installed
And the last step was to celebrate the instal with a free victory beer!
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I look forward to your questions and comments.
Here is a list of the tools and products I used to make these:
Runner Up in the
Make it Glow Contest 2016