Metal Candlestick of Your Favorite Figure

I do like those tiny candlesticks and I have made many by now. Now Christmas time is coming and what is Christmas without Charlie Brown and his Christmas tree? I had to make one more. A Charlie Brown candlestick. Look here if you do not know Charlie Brown:

https://www.youtube.com/watch?v=jEMIugqZYfM

In this Instructables I will show you how to make a candlestick in metal. You will not need so many tools and can work with some small left over pieces of metal so it will cost you almost anything. This candlestick maybe makes an excellent Christmas gift? All of the work is done by hand, and some of you may wonder ‘why would you cut by hand when you can use a CNC machine?’ The simple answer is that I do not own or have access to a CNC and actually I find it quit peaceful to sit down by my dining table or in my little workshop and cut some metal by hand.

I went on internet and selected a picture of our fellow and printed it in the size for my candlestick (see step 2 below). I have used copper but you can use any kind of metal. The advantage of copper is that it is soft and easy to work with.

Supplies

Metal I used, copper 1,2 mm (o,47 inch) but it will do with 1 mm as well
Rasp for metal
Glue stick, paper, picture/template
Jewelry saw or jigsaw, saw blade for metal no 3
V shaped Bench peg
pillar drill or screwdriver
drill bit 1 mm
Clamp
epoxy glue
Sand paper 240 grit
Spray paint. I use Montana Gold
Some scrap wood
Copper pipe (Dimention depents on the diameter of your candlestick)
Pipe cutter or hacksaw
Clothespin or small clamps
Double-sided tape
Candle stick

Step 1: Choose Your Design

There are soooo many figures..... Which design do you choose?

Step 2: Let's Start With Charlie Brown

Measurements: Charlie Brown is 8.5 cm (3.35 inch), The Christmas tree is 7 cm (2,75 inch) and the plate is 11,5 cm x 3,5 cm (4.53 x 1,38 inch).

Grind your metal with sandpaper 240 grit.

Cut out your paper print and glue your design on the copperplate with either a glue stick or wood glue.

Let dry a couple of minutes.

Cut out your plate with a shears or cut it with your jewelry saw leaving good space around the fine details of your figure.

Step 3: Drill Holes Before Sawing

Before you start to drill: Make an indentation with a nail and a hammer to prevent the drill from slipping away.

When your design contains very small details you can drill some holes in advance. This will make it easier.

Drill with a pillar drill or screwdriver. I used a 1 mm drill.

You will get some burs on the backside, so smoothen with a rasp.

Step 4: The Fun Part

Prepare your jewelry saw (or jigsaw). I used a blade for metal number 3. Be sure the blade is properly mounted with the teeth facing downward so that they cut on the down stroke of the blade.

I apply some wax on the sawblade before I start so it will be easier to saw by reducing friction.

Make a notch by holding your saw 45 degrees. Than angel your blade to 90 degrees and saw with very little pressure. Make sure to clean the sawdust whilst working so that you can clearly see the lines.

If you want some more ticks and tips look here: https://www.youtube.com/watch?v=aR5iN9Qmw7c

Wet your paper figure to remove it from the metal.

Use a rasp to smoothen the edges and sand the surface once again with 240 sandpaper. This will give you very smooth edges.

Step 5: The Christmas Tree and Christmas Boll

Continue with the tree and the little Christmas boll as I described in step 5.

The tree was more difficult than Charlie Brown as it is fragile with many small details. I clamped it on the bench peg.

You can also put it on a tiny piece of scrap wood for more support.

Step 6: The Ground Plate

Cut or saw your ground plate. My plate is 11,5 cm (4.53 inch) by 3,5 cm (1,38 inch).

Sand and file the edges smooth.

How to mount your figure precisely: I mounted Charlie in the ground plate by cutting an opening with the same size as the length of Charlie’s feeds and the width of the copper/metal that you use. If you do this carefully, than Charlie will fit properly in the opening.

Mark the middle of the ground plate.

Make two marks at start and end with a nail and a hammer.

Drill holes and saw a gap with a width of 1,2 mm so that Charlie fits perfect.

Repeat this for the Christmas tree. Look at my pictures and you will get it.

Step 7: Cut Your Pipe for the Candle Holder

For this candlestick I use a small candle (you can either use a real candle or a child-friendly LED candle).

The dimension of your copper pipe depends on the size of the candle sticks you use. I used a copper pipe with an inner dimension of 12 mm (0,47 inch).

Cut the copper pipe with a pipe cutter. My candle light holder is 1,2 cm high (0,47 inch)

You can also sawing your pipe using a hacksaw.

Sand both ends of your pipe.

Step 8: Glue the Parts Together With Epoxy

I have choosen to glue the metal together instead of hard soldering. The problem with hard soldering is that this softens the metal and requires extra equipment. Epoxy is cheap, it works fast and gives you a strong joint.

Remember safety first: the bare minimum for working with epoxy is gloves, eye protection, and protective clothing. Do you want to know more about working with epoxy? Look here:

https://entropyresins.com/safety/epoxy-safety-tips/#:~:text=Wear%20goggles%2C%20safety%20glasses%2C%20gloves,with%20an%20organic%20vapor%20cartridge.

Before you mix your epoxy verify if all the parts fit nicely.

Mix the epoxy and apply it on your figure and all other parts that you want to mount on the ground plate.

I used clothespins to keep the parts in a 90 degree angle during drying (check instructions on your glue on drying time).

Step 9: Let's Paint

Before spray painting I did a final sanding of the whole candlestick to remove glue, dirt and grease so that the paint would nicely adhere.

I mounted the candlestick on a long piece of wood using double sided tape, so that I could hold the candle stick during spray painting.

Safety first. Put on your mask, gloves and googles before painting. I prefer to paint in the open air. If that’s not possible paint in a room with good ventilation.

Shake the spray paint well before use.

Apply several light coats of paint, and allow each layer to dry before applying the next layer. In my case I sprayed two layers of paint.

I put on the Christmas ball on a very tin steel wire.

The clothes pin helped me to hold the Christmas boll while painting.

Mount the Christmas boll after the paint has dried by bending the wire around a branch.