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

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!

Nails!

Step 12: Wire It Up!

Wiring up & installing the sockets.

Step 13: It's Alive!

Victory!

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)

Zack

ZH Fabrications

Comments

author
bassam704 (author)2017-05-02

Beautifullllllll!!!!!

author
tranzit1260 (author)2017-03-12

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

author
wile222 (author)2017-01-28

Would you mind sharing your source for your light sockets?

author
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

author
wile222 (author)ZH Fabrications2017-02-10

Thank you :)

author
tranzit1260 (author)2017-01-14

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

author
tranzit1260 (author)tranzit12602017-01-26

Жаль что не ответили (((

author
stoneandsonsworkshop (author)2017-01-20

Voted!

author

Thanks Shawn!

author
Crumpred (author)2017-01-10

Mad skills Zack ... Thanks!

author
ZH Fabrications (author)Crumpred2017-01-23

Thanks!

author
ZH Fabrications (author)Crumpred2017-01-15

Thank you!

author
Bernie40 (author)2017-01-10

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

author
ZH Fabrications (author)Bernie402017-01-15

Thanks!

author
clazman (author)2017-01-10

You're the MAN!!

A true artisan!

author
ZH Fabrications (author)clazman2017-01-15

Thank you!

author
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!

author
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!

author
bzmaker (author)2017-01-10

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

author
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

author
seamster (author)2017-01-10

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

author
ZH Fabrications (author)seamster2017-01-15

Thanks!

author
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

author
ZH Fabrications (author)deluges2017-01-15

Thank you!

author
ColmH1 (author)2017-01-15

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

author
4DIYers (author)2017-01-09

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

author
ZH Fabrications (author)4DIYers2017-01-09

Thank you!

author
RushNafikov (author)2017-01-06

Awesome lights! what light bulbs did you use?

author

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

author

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

author
ClenseYourPallet (author)2017-01-06

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

author

Thank you!

author
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!

author

Thank you!

author
abearman3000 (author)2017-01-06

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

author

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

author
woodbywright (author)2017-01-07

Sweetness man!

author

Thanks James!

author
TheRedsmith (author)2017-01-07

Very cool !

author

Thanks!

author
3366carlos (author)2017-01-07

professional work. Very nice.

author

Thank you!

author
JörgenBörg (author)2017-01-07

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

author

Thanks!

author
DanL63 (author)2017-01-07

killer details! voted

author
ZH Fabrications (author)DanL632017-01-09

Thank you!

author
tonginos (author)2017-01-07

Smooth!

author
ZH Fabrications (author)tonginos2017-01-09

Thanks!

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

Beautiful work!

author

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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