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!

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

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

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!

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)


ZH Fabrications

<p>Зак спасибо за ответ !!! Теперь я сделаю это !!! Отлично !</p>
<p>Would you mind sharing your source for your light sockets?</p>
<p>Hey, sorry your message slipped under my radar. Here is a link to the sockets I used: http://amzn.to/2lwnI6c</p>
<p>Thank you :)</p>
<p>Зак , добрый день ! Где покупали патрон для лампы . Мне такой не найти (((</p>
<p>Жаль что не ответили ((( </p>
<p>Thanks Shawn!</p>
<p>Mad skills Zack ... Thanks!</p>
<p>Thank you!</p>
<p>Great work and good video! A pleasure to watch and to learn, thank's a lot :)</p>
<p>You're the MAN!!</p><p>A true artisan!</p>
<p>Thank you!</p>
I must say... I saw this in my email and thought, &quot;Perfect, just what I'm looking for right now! Shouldn't be too hard.&quot; 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, &quot;Shut Up!!!&quot; And to be doing it from your garage! I know you must be underpaid. <br>You are a walking talent! Great video!
<p>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.<br><br>Thanks again for the compliments!</p>
<p>That is a sweet project, Zack! How do you do the blackened metal patina?</p>
<p>Thanks, I use a product called &quot;Black Magic&quot; By Sculpt Nouveau, I will actually be giving some away on a huge giveaway I have coming up on my youtube channel</p>
<p>You've got a new fan right here. Beautiful, inspiring work, and mad skills all around. Bravo!! :)</p>
<p>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</p>
<p>Thank you!</p>
I liked having a sconce at your sconce - thank you ?
<p>Beautiful work! Always love the custom made aspect, gives your own personal touch and no one else has it. </p>
<p>Thank you!</p>
<p>Awesome lights! what light bulbs did you use?</p>
<p>Thanks! They are T-9 longs, I have a link in the last step.</p>
<p>Thanks... I forgot to add it to the list... I just added it in the description, but here is the direct link: <a href="http://amzn.to/2fAGbAC" rel="nofollow">http://amzn.to/2fAGbAC</a></p>
These are amazing lights! I really like the nails. Voted
<p>Thank you!</p>
I saw this video on YouTube around a week ago, and absolutely love it! You truly are a craftsman! Absolutely brilliant!
<p>Thank you!</p>
<p>Wow. So very cool. Where did you learn all these skills? That metal ripping table saw is wicked.</p>
<p>Thanks! Just lots of messing around I suppose. And yeah the cold saw is a beast!</p>
<p>Sweetness man!</p>
<p>Thanks James!</p>
<p>Very cool !</p>
<p>professional work. Very nice.</p>
<p>Thank you!</p>
<p>very nice work. this is high quality work! :-)</p>
killer details! voted
<p>Thank you!</p>
<p>Beautiful work!</p>
<p>Thank you!</p>

About This Instructable




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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