Introduction: Make a No Weld Metal Hanging Lantern
This is an Instructable for a simple and elegant hanging metal lantern. The lantern is constructed from perforated patterned metal to create a nice light and shadow effect. This Instructable will teach you how to fold sheet metal in a way to make a strong joint.
Step 1: Step 1: MATERIALS // TOOLS
/ Decorative Perforated Metal http://www.accuratealloys.com/decorative-perforate...
/ Metal Wire
/ Tin Snips or a Jig Saw with a metal cutting blade
/ Cut resistant Gloves http://www.globalindustrial.com/p/safety/hands/cut...
/ Piece of wood or metal bender http://www.harborfreight.com/18-inch-bending-brake...
/ Spray Paint
Step 2: MEASURE THE PIECES
/ Cut the metal in various sized strips, I varied the dimensions from 7" x 20" to 4" x 18" going any smaller or bigger becomes difficult to bend or too big to hang
/ Use a Sharpie to draw a line on the metal for your cut line
Step 3: CUT THE METAL
/ Use the tin snips and follow the line
/ Be sure to wear cut resistant gloves because the edges are extremely sharp
/ This method works well for patterns with less metal, its pretty hard on your hands but leaves a clean cut
/ Use a Jig Saw with a metal cutting blade
/ Be sure to wear eye protection because it does shoot little pieces of metal everywhere
/ This method is Loud and does leave a jagged edge but is quick and easy
Step 4: BEND THE METAL ENDS
/ To attach the ends of the lantern you need to bend the sheet metal ends in opposite directions
/ The end bends should be no more than 1" (anything more begins to warp the shape)
/ You can get away with about 1/4" bends on the smaller lanterns (Its difficult to bend it any smaller)
/ Using a Metal bender secure the sheet metal and bend the ends
/ This method is easy, fast and works the best but requires the tool
/ Clamp a piece of wood over the ends of the sheet metal and bend the ends upwards
/ I was able to bend the pieces just using my hands but it was tiring (tiring enough to make me to purchase a metal bender)
Step 5: HAMMER DOWN THE BENDS
/ Using the mallet hammer the bends so they create a flatter hook
/ Be sure not to hammer the folds too flat because they're going to need to hook together
Step 6: SHAPE THE LANTERNS
/ Use the side of a table and press the sheet metal while slowly rotating the metal to create its cylindrical shape
/ Be sure to wear gloves and try and be consistent in your bends to create a nice curve
Step 7: HOOK THE PIECES TOGETHER
/ Using the bends at each ends hook them together to create the joint
/ It takes a bit of practice to get the folds flat enough but not too flat so that you cant get them together
/ The metal's springiness will create enough tension to keep the joint in place and strong
Step 8: PINCH THE FOLD FLAT
/ Use a pliers to pinch the joint flat, this is both for aesthetics and to make sure it does not come apart
Step 9: PREP & PAINT THE LANTERNS
/ Use the Simple Green metal cleaner to degrease the metal
/ Paint the lanterns using spray paint
Step 10: HANG THE LANTERNS
/ My dad ended up hanging the lanterns in their backyard and sent me this video
/ He used the metal wire and strung the lanterns across an existing string of lights
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