Porcelain Light Fixture

Materials:

cone 10 porcelain clay
lacquer
squeeze bottle
cone 10 green glaze
steel tubing
metal primer
rubberized auto coating
spray paint
auto body bondo
50/50 vinegar and water mixture in spray bottle
under-the-counter fluorescent lights
screws and nuts for mounting
1/2" rubber pads
light cord
colored caulking
E-6000 glue
kiln
safety glasses and welding face shield
welding torch
welding gloves
slab roller
rectangular "cookie cutter" tool
rectangular stencil divided into 6 panes
paintbrush
bucket of water
sponge
paint sprayer
respirator mask
sandblaster
lacquer thinner

Steps:

Porcelain Tiles

1. Wedge and cut the clay.

2. Feed the clay through a slab roller (figure A) and let dry.

3. Cut out five rectangular tiles using a pre-made rectangular "cookie cutter" tool and let air dry to a bone-dry state, about seven days (figure B).

4. Sand and water-wipe the edges, then pencil in lines from the stencil (figure C).

5. Brush on lacquer onto the border edges and the crossbars of the panes (figure D). Drizzle on a design within each pane of each rectangle using lacquer from a squeeze bottle and let dry (figure E).

6. Spray the clay rectangles with a mixture of 50/50 vinegar and water solution. Wipe with a wet sponge as this will etch the clay where there is no lacquer (figure F). When dry, repeat this step two more times.

7. Bisque fire tiles in kiln for 12 hours.

8. Sand off the lacquer residue with sandpaper. Glaze the tiles wiht green glaze and a paint sprayer (figure G). Wear eye protection and a respirator mask while glazing.

9. Glaze fire the tiles.

10. Sand blast the tiles using a sandblasting machine (figure H).

Metal Frame

11. Measure and cut the steel, then wipe clean with lacquer thinner.

12. Grind the steel ends and the surface.

13. Weld the frame together and drill holes for hanging (figure I).

14. Weld metal supports for the tile onto the frame.

15. Grind weld and clean with lacquer thinner.

16. Mix and apply bondo onto the metal frame.

17. Sand the metal frame and wipe clean with lacquer thinner.

19. Sand lightly.

20. Spray desired paint color onto frame.

21. Mount lighting brackets and insert lights (figure K).

22. Set the rubber-mounting brackets.

Website: www.pecktile.com