Introduction: Big Bad Vader Log Burner

Picture of Big Bad Vader Log Burner

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

Picture of 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

Picture of Mouth Detailing

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

Step 3: Hinge

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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.

Step 8: Burn Vader Burn

Picture of Burn Vader Burn

Before painting with UHT paint I decided to give is a test burn, this will also burn off any of the remaining original paint.

Step 9: Matt Black

Picture of Matt Black

I gave vader 2 coats of UHT black paint and it's good to go.

If you like it please vote...thanks for looking...


doddieszoomer (author)2014-08-10

If you interested in having one of these made please contact me on

KramN made it! (author)2015-09-15

variation #,

natascha.wiedenfeld (author)2014-09-23

Holy Shit, this looks awesome!!!

TrollFaceTheMan (author)2014-08-15

Haha, very cool!

nancyjohns (author)2014-08-06

the storm troopers will ba scared as ever!

sthebeau (author)2014-08-05

Yes would love to know if any on selling sites

knutknackebröd (author)2014-08-05

soooo I guess he joined the light side?

Gamer Guy (author)2014-08-04

Vader's still just as hot as he was on Mustafar. Awesome job!!!

spark master (author)2014-08-04


awesomeness with a welder

Ricardo Furioso (author)2014-08-04




bethehammer (author)2014-08-03

That is awesome!

doddieszoomer (author)2014-08-03

Buy it now or best offer

thoms_here (author)2014-08-03

What a great looking burner and just an awesome idea!

nintenbro64 (author)2014-08-03

This looks amazing, great job!!

parapedro (author)2014-08-03

Great work man. Much better than the old plain gas bottle I've been using.

Gotta make one for my next camp-out.

PikesPeak (author)2014-08-03

Very very nice, and very well done.

Jutamuse (author)2014-08-03

Congratulations!!!Wonderfull burner!!!

dusty-ems (author)2014-08-03


eugenioca (author)2014-08-03

Nice very nice 10 points :))), voted and favorite :))).

3366carlos (author)2014-08-02

i voted for you man!

instructable person 9 (author)2014-08-02

Epicly awesome!!!!!!!

wobbler (author)2014-08-02

Star Wawesome!

mitch5007 (author)2014-08-02

Love it mate

mcogan (author)2014-08-01

that my friend is legend!

andrea biffi (author)2014-08-01

those burners are impressive! congrats!

poofrabbit (author)2014-08-01

Very well done again! I love it larger to burn logs. Did you put one on ebay? I loved your first one, but I think you are even more spot on with your second! LOVE LOVE LOVE! When the voting pannel comes up I promise to come back and vote. :)

crank_girl (author)2014-08-01


skepticaljay (author)2014-08-01

Completely wonderful!!!!!!!!!!!

About This Instructable




Bio: Since the dawn of Lego I've been into making stuff... I'm currently a technology teacher at a secondary school tasked with inspiring the ... More »
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