Introduction: Industrial Style Wall Sconces

Hey!

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.

Thank you!
Zack

Step 1: Cutting the Frame

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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!

Picture of Fire!

I also torched the chamfer to heighten the contrast once the piece is assembled and stained.

Step 7: Mock-up

Picture of 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

Picture of Staining & Finishing

I stained the panels using a dark walnut gel stain in the chamfers and a slightly lighter gel stain (Candelight) for the entire panel. Here I'm spraying a water based polyurethane clear coat.

Step 9: Final Mock-up

Picture of 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

Picture of 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!

Picture of Nails!

Nails!

Step 12: Wire It Up!

Picture of Wire It Up!

Wiring up & installing the sockets.

Step 13: It's Alive!

Picture of It's Alive!

Victory!

Step 14: Installed

Picture of Installed

And the last step was to celebrate the instal with a free victory beer!

If you liked this and would like to support me, I invite you to subscribe to my YouTube channel, it really helps me out.

I look forward to your questions and comments.

Here is a list of the tools and products I used to make these:

Bulb-T9 Long

DeWalt DW872 cold saw

DeWalt DWE4011 Angle Grinder

Dewalt DW618 plunge/fixed base router

Lincoln 140C Mig Welder

General Finishes Antique Walnut Gel Stain

General Finishes Candlelight Gel Stain

General Finishes High Performance Top Coat(Gloss)

Zack

ZH Fabrications

Comments

bassam704 (author)2017-05-02

Beautifullllllll!!!!!

tranzit1260 (author)2017-03-12

Зак спасибо за ответ !!! Теперь я сделаю это !!! Отлично !

wile222 (author)2017-01-28

Would you mind sharing your source for your light sockets?

ZH Fabrications (author)wile2222017-02-10

Hey, sorry your message slipped under my radar. Here is a link to the sockets I used: http://amzn.to/2lwnI6c

wile222 (author)ZH Fabrications2017-02-10

Thank you :)

tranzit1260 (author)2017-01-14

Зак , добрый день ! Где покупали патрон для лампы . Мне такой не найти (((

tranzit1260 (author)tranzit12602017-01-26

Жаль что не ответили (((

stoneandsonsworkshop (author)2017-01-20

Voted!

Thanks Shawn!

Crumpred (author)2017-01-10

Mad skills Zack ... Thanks!

ZH Fabrications (author)Crumpred2017-01-23

Thanks!

ZH Fabrications (author)Crumpred2017-01-15

Thank you!

Bernie40 (author)2017-01-10

Great work and good video! A pleasure to watch and to learn, thank's a lot :)

ZH Fabrications (author)Bernie402017-01-15

Thanks!

clazman (author)2017-01-10

You're the MAN!!

A true artisan!

ZH Fabrications (author)clazman2017-01-15

Thank you!

PPDB33 (author)2017-01-10

I must say... I saw this in my email and thought, "Perfect, just what I'm looking for right now! Shouldn't be too hard." Ha!!! I can't believe your skill from welding to finishing, and when you got to the part of iron working and forging your own nails, I literally said, "Shut Up!!!" And to be doing it from your garage! I know you must be underpaid.
You are a walking talent! Great video!

ZH Fabrications (author)PPDB332017-01-15

Hah, thank you! Yeah, I just set up a Patreon and I'm still working on the underpaid part, but I think things are just going to keep getting better.

Thanks again for the compliments!

bzmaker (author)2017-01-10

That is a sweet project, Zack! How do you do the blackened metal patina?

ZH Fabrications (author)bzmaker2017-01-15

Thanks, I use a product called "Black Magic" By Sculpt Nouveau, I will actually be giving some away on a huge giveaway I have coming up on my youtube channel

seamster (author)2017-01-10

You've got a new fan right here. Beautiful, inspiring work, and mad skills all around. Bravo!! :)

ZH Fabrications (author)seamster2017-01-15

Thanks!

deluges (author)2017-01-10

That's one amazing project. The video was extremely enjoyable to watch, top notch craftsmanship, great choice of music as well. And I learned how to make your own nails. What a day

ZH Fabrications (author)deluges2017-01-15

Thank you!

ColmH1 (author)2017-01-15

I liked having a sconce at your sconce - thank you ?

4DIYers (author)2017-01-09

Beautiful work! Always love the custom made aspect, gives your own personal touch and no one else has it.

ZH Fabrications (author)4DIYers2017-01-09

Thank you!

RushNafikov (author)2017-01-06

Awesome lights! what light bulbs did you use?

Thanks! They are T-9 longs, I have a link in the last step.

Thanks... I forgot to add it to the list... I just added it in the description, but here is the direct link: http://amzn.to/2fAGbAC

ClenseYourPallet (author)2017-01-06

These are amazing lights! I really like the nails. Voted

Thank you!

Modern Rustic Workshop (author)2017-01-06

I saw this video on YouTube around a week ago, and absolutely love it! You truly are a craftsman! Absolutely brilliant!

Thank you!

abearman3000 (author)2017-01-06

Wow. So very cool. Where did you learn all these skills? That metal ripping table saw is wicked.

Thanks! Just lots of messing around I suppose. And yeah the cold saw is a beast!

woodbywright (author)2017-01-07

Sweetness man!

Thanks James!

TheRedsmith (author)2017-01-07

Very cool !

Thanks!

3366carlos (author)2017-01-07

professional work. Very nice.

Thank you!

JörgenBörg (author)2017-01-07

very nice work. this is high quality work! :-)

Thanks!

DanL63 (author)2017-01-07

killer details! voted

ZH Fabrications (author)DanL632017-01-09

Thank you!

ZepLabs (author)2017-01-07

Smooth!

ZH Fabrications (author)ZepLabs2017-01-09

Thanks!

Dui ni shuo de dui (author)2017-01-07

Beautiful work!

Thank you!

About This Instructable

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Bio: My name is Zack, I'm a full time craftsman. I am incredibly fortunate to be able to do what I love full time--turning ideas ... More »
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