Industrial Style Wall Sconces

11 Materials
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'm limited to only 15 images, some of the detail in the video isn'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!
Here is the video, this is going to provide the most detailed & entertaining way to see the process.
The first step was to cut out the frame. I used a DeWalt cold saw for this. I truly believe this to be the most deafening tool one can own!
With the pieces for the frame cut, the next step was to weld the frame together.
After cutting out some 2x3 square tubing(Cold saw again), I'm de-burring the holes I drilled which will later accept the bulb.
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.
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.
I also torched the chamfer to heighten the contrast one the piece is assembled and stained.
With the panel glued up, and routed for the socket frame--this is the mockup assembly
I stained the panels using a dark walnut in the chamfers and a slightly lighter color for the entire panel. Here I'm spraying a water based polyurethane clear coat.
Getting closer, this is the final mock-up with the blackened metal patina, and stained & clear coated panels.
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.
The next step was wiring these things up!
It's alive!
And the last step was to celebrate the instal with a free victory beer!
Thanks for watching guys! I look forward to your questions and comments.
ZH Fabrications
Tools Finishes & Bulb Used:
Lincoln Electric 140C Mig welder -
Dewalt 4 1/2 Angle Grinder -
Dewalt DW862 Cold Saw -
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) -
Bulb - T9 Long -

Resources for this project:

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