How to Make a Stainless Steel Surfer Light Fixture

Create a surfer-style light fixture from stainless steel and glass with these steps.
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Materials and Tools:

20-gauge stainless steel
stainless steel tube
light-socket kit
double-stick tape
blue stain glass
computer and scanner
laser cutting machine
software for laser cutter
plasma cutter
MIG welder
welding-safety equipment, including gloves and face mask
glass cutter
sheet-metal straight hand brake machine
photo
masking tape
hand tube bender
tube cutter
clamps
screwdriver
straightedge
light buffing pad

Steps:

1. Scan a photo into the computer and create a black-and-white negative using photo imaging software.

2. Convert the image to the appropriate file type using laser cutting software and send the file to the laser cutting machine.

3. Laser-cut the flat surfer and floral patterns on stainless steel.

4. Laser-cut the main body.

5. Laser-cut the top.

6. Laser-cut the back plate.

7. Apply masking tape to the front edges of all stainless pieces to prevent scratching.

 

8. Bend the lamp sides at 90-degree angles to form the main body of the light fixture using a hand brake machine.

9. Bend the four edges of the back plate and form the top with a pitched roof.

10. Bend a length of stainless steel tube at a 90-degree angle for the lamp cord.

11. Cut the tube with a tube cutter.

 

12. Wearing protective gear, weld the main body, the top and the base together with a MIG welder. Weld the stainless steel tube to the inside of the back plate. Hold the parts together with clamps while welding.

13. Clean the welds.

14. Install the light-bulb socket by threading the cord through the stainless steel tube in the back plate.

15. Screw the socket into place.

16. Score and break three stained-glass pieces to size for the side panels with a glass cutter and a straightedge. Smooth the edges of the glass.

17. Apply double-stick tape to the edges of each glass piece. Press the stained glass onto the inside of the three side panels of the light fixture.

18. Buff the stainless steel with a light buffing pad.

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