Make a No Weld Metal Hanging Lantern

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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

MATERIALS

/ Decorative Perforated Metal http://www.accuratealloys.com/decorative-perforate...

/ Metal Wire

TOOLS

/ Tin Snips or a Jig Saw with a metal cutting blade

/ Ruler

/ Sharpie

/ Cut resistant Gloves http://www.globalindustrial.com/p/safety/hands/cut...

/ De-greaser http://www.staples.com/office/supplies/StaplesProd...

/ Mallot http://www.lewiscontractorsales.com/Merchant2/merc...

/ 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

METHOD 1

/ 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

METHOD 2

/ 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)

METHOD 1

/ 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

METHOD 2

/ 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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    user

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    4 Comments

    user

    that's awesome! I have a few very dangerous to bare hands 'icicles' and spirals from metal shavings at work hung on the big Christmas lights. This idea seems safer around the house.

    Great

    These look excellent!

    I love the simple construction too. So nice! :)