Back by popular demand.

The last few vader log burners I've made have caused quite a storm. With this one I wanted to go bigger and badder and try and capture more of the original shape and styling.

The bottle I used was a 46kg I think...yeah pretty big...

Step 1: Marking Out

I magic marketed the face and cut the details out using my drill, 10mm bit and angle grinder with 1.2mm blade...I used a few of these!!

The plan was to cut the bottom off and use the lower section of the cylinder for the hood of the helmet.

Step 2: Mouth Detailing

I welded two bolts into the corner of the triangle to add styling.

Step 3: Hinge

I always fit the hinge before cutting the door so I know it'll always hang straight.

Mark out using a marker pen, drill 3mm hole and tap using a 4mm tapping wrench. The hinge is fitted with 4mm x 10mm machine screws.

Step 4: Bridges

One the bridge of the nose I welded a tube which I had split and cut creating more detailing.

Step 5: Thermal Exhaust Ports

I has running low on scrap buys of metal and with school out for the summer I had to improvise.

My first design used 3 scaffolding tubes welded together but I thought is sucked so ended up cutting them off and going with a 6 tier exhaust which I'm much happier with.

Step 6: Weld and Grind

The eyebrow pieces, Cheek detailing and handle are made from the left over cylinder. I also used a large section of the cylinder to create vaders hood.

Once welded I used a flap wheel fitted to my grinder to smooth all rough edges and strip the paint.

Step 7: Daddy Vader

At the side of a regular sized gas bottle you can see the big vader towers over my previous design.

The original is a 13 or 15kg gas bottle, the big one I think was a 46kg.