In this Instructable I am going to explain how to make a Bourbon Bottle Tiki Torch. Of course, you will be able to make a variety of torches for beer or wine bottles as well. These are fun for BBQ's, camping or just watching the sunset off of your back porch. #metalcontest
Step 1: Gathering Your Tools and Materials
For this instructable you will need to know how to use a forge or a torch. This project deals with extreme temperatures and can be dangerous. Please use all safety equipment necessary including goggles and a method to extinguish fires that may occur. I make no claim of warranty or liability for your trying to replicate this project.
1. Empty Bourbon Bottle (or your favorite spirit)
2. Copper 3/4 to 1/2 inch pipe reducer
3. 3/4 inch tiki torch wick (commonly found in your outdoor section of your favorite hardware store)
4. Electrical Tape (high temp)
5. Teflon Tape
6. 1/2" steel rod,rebar, or other non galvanized pieces you wish to recycle, reuse, or repurpose
7. Citronella Tiki Oil
8. Bench Vise
9. 5 gallon bucket or other water cooling barrel
10. Oxyacetylene torch or forge
11. Safety Goggles
12. Leather Apron
13. Fire Extinguisher
14. optional: In this instructable I am free handing the shape for my bottle. However,you can use a scrap block of wood or scrap pipe. A piece of scrap pipe the diameter of your beer or wine bottle is very helpful when making round torch holders.
Step 2: Bending the Tiki Stand
This can be done several ways. For this project we are free handing a rectangle to hold the bottle we have chosen. I just measured the bottle and am making bends a 1/4 in larger so that the bottle sets in easily, yet securely. It is important to have safety glasses and the appropriate gloves. You will be dealing with fire in excess of 2000 degrees. We are not trying to melt the metal so we only want to get it to about 1800-1900 degrees. If it starts popping then you are getting it too hot and it will then melt and sag. We only want to get to a bright red/orange glow. If it you get to white hot you are already melting the piece. It is also important to have a fire extinguisher and bucket of water. The water is mainly for cooling the metal in between bends. When we are heating our metal we only are heating a couple of inches at a time to make each curve. We are not heating the straight runs. Below are more pictures of this process.
** I will also make a note that if you are using a wine bottle and a short piece of pipe to curve around. You are heating the entire piece but only a few inches at a time as you work the metal around the pipe jig.
Step 3: Making the Bottle Into a Tiki Torch
This is my first instructable. I am working on taking better step by step pics. This is an easy step. This step will use our 1/2" to 3/4" copper reducer, teflon tape, electrical tape, wick and lamp oil. For any bottle we want to start by making a wrap of electrical tape around the mouth of the bottle with a clean cut so that it is all nice and neat. We then take our teflon tape and make a few wraps around the 3/4" side (larger side) of the reducer. The piece should fit snug in the mouth of the bottle. If it is still loose make a few more wraps of teflon tape. Then take the wick and thread it through leaving about a quarter inch exposed at the top. Fill the bottle with citronella oil or some colored lamp oil. The Tiki bottle is complete. One more step and we are all done.
**note: The copper reducer is versatile for almost all bottles. Wine bottles will also use the 3/4" side in the mouth and beer bottle like the one pictured uses the 1/2" end inside the bottle.
Step 4: Final Step: Mounting the Tiki and Lighting
This is a fun step. Of course, this is decided before we forge the stand. The Tiki can be mounted in a variety of ways. I like to make post or wall mounts. These are great for patios or along fences. I mounted the bourbon bottle tiki in a block of wood but they can also be staked into the ground along walk paths and patio borders. The lighting of the Tiki is easy. Just light with a match or lighter. You can adjust the height of the flame by raising or lowering the exposed wick. DO NOT let the wick run dry. Additionally the wick can be capped by a copper cap from the plumbing section. Depending on the end you have exposed you can use a 1/2" or 3/4" cap to cover the unlit wick to protect it from moisture. Store in a cool dry place for prolonged storage as the wick will gather water and wick it down into the bottle. I hope that you enjoy this instructable and it helps you enjoy your next evening on the patio without mosquitoes.