Here is a video tutorial that shows an overview of the build.
Here is a photo showing the video shoot. To film and record the project I used a Canon Vixia HF S21 Video Camera along with a Nikon D5100 SLR Camera. I used a couple Chevy pickups to get descent light!
Cutting letters by hand takes some time, so take a few breaks during the process and make sure you have good ventilation.
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Each wall tells a story and has memories. Designing your own metal wall art can have just as many memories. Think of it as a project that you could do as a family. Try not to get too carried away with complex designs because once you start using the metal, shaping it is easier said than done. Stick to the simpler designs until you get the hang of it.
Next, I created stencils using my vinyl plotter. This is seriously one of the handiest pieces of equipment and if you are into metal working you’ll be able to create any stencil you’d ever need. I got my Graphtec 24″ vinyl plotter here. Vinyl stencil of the EntrepreneurOnFire logo.
Metal – 10 gauge for panels — 12 to 14 gauge for letters 3/4 inch square tube for frame 3/8 inch threaded rod, nuts, and washers for layering metal Spray paint Metal Sealer – (Available at any hardware store) Stencils for the design – I made mine using my Graphtec CE-6000 Vinyl Plotter Two part epoxy Chain, eyebolts, and metal clasps Cleat to hang project
Below are additional stencils for the San Diego silhouette and words. After applying the decal I traced around each letter and design using a sharpie marker. This gave me a good visual to follow with the plasma cutter. Make sure to remove the decal prior to cutting because it will burn up and stick to the metal.
Prior to attaching the cut-out letters, I put stencils down and traced around them with a pencil. After tracing, you’ll want to remove the stencil. The pencil lines were helpful for making sure I glued the letters in the correct spot in the next step.
Here is the outline of the microphone in the Entrepreneur On Fire logo.
I used a cleat system to mount the sign. It makes mounting heavy things super easy. Just make sure to use a stud finder to attach the cleat to the studs in your wall.
Now for the shipping. I built a custom box that was 67″ long x 21″ wide x 7 inches tall. The final weight of the package was 112 pounds. The total shipping cost using my Fedex business account was only $68. I couldn’t believe how cheap it was! (Would have been about $85 without the account.)
To create dimension, I used 3/8 inch threaded rod as spacers and a few bolts.
John was born in Alfred, Maine. To personalize the sign I created a cutout of Maine on the left side. San Diego is where he lives now. The metal on the right is the San Diego skyline. I wanted to incorporate his name as well, which is why I added the chains and plaque.
Plan ahead of where you intend to hang the art. You should have a clear idea of which wall you will use and the size you would like for the artwork to be. Metal art can be a powerful statement, keep it in mind so that you plan the better half of your wall with the art. You can keep it small and clean cut, to make it look classy and expensive. Or, you can choose an oversized artwork to make a bold statement.
Once the design is ready, take a second look and make sure the design has a good composition. It should be a simple design, with several elements so that there is not a lack of unity. Metal art is heavy, therefore make sure to hang it on a solid brick, stone or concrete wall. Additionally, do not use ordinary screws for your metal art but purchase some heavy duty bolts or hooks for the extra support needed.
Designing Your Own Metal Wall Art Designing Your Own Metal Wall Art
I created a separate stencil to create a perfectly round metal circle.
I used a 1/2 drill bit to put holes in the back panel to put the threaded rod through and attach the multiple layers.
Chains were added to attach the name plate. An eyebolt and clasp worked great for connecting the chain to the steel tubing.
I picked up 10 gauge steel for the panels on this project and used 12-14 gauge for the letters. I also purchased 1 inch square tubing to frame out the piece. The total cost for steel was right around $95. Thanks Pacific Steel!
Time to get out the plasma cutter! This tool is a blast to use and is very easy to master. You just have to follow the lines you drew and make sure to hold the tool as steady as possible. I used the Hobart 250CI plasma cutter that simply plugs into a normal 110V wall plugin.Here I am following the outline I drew of a circle. Wear plasma cutting eye goggles and a respirator.
Here is a look at the back panel cut to size and the completed circle.
I set all the designs on the metal to see how everything looked. So far so good!
I had an idea for a project that I wanted to make and John’s business was the perfect fit. I could incorporate multiple layers of metal, a city skyline silhouette, map, and fire! In this tutorial I will show the basic steps I took to build this metal sign. It weighs 80 pounds and is nearly 6 feet wide by 2 feet tall.
Thanks for checking out this DIY metal project! I hope it inspires you to start creating with metal. Check out my resources page if you are interested in finding out the tools I recommend for fellow DIY’ers. Lastly, please subscribe to my Youtube channel and like my Facebook page if you enjoy the DIY Projects on my site. It would help spread the word and inspire others to start creating! Cheers – DIY PETE
I attached the metal letters using a 2 part epoxy. A popsicle stick came in handy for spreading the glue on each letter. You can see the pencil outlines used to help line up the design.
I decided to give all the letters and designs a bright polished look. To remove the greasy film on the metal I soaked the letters in muriatic acid. Let them sit for about 10 minutes and then rinse in water with a little baking soda to neutralize the reaction. Pat dry with a clean rag. Dry them as soon as possible because they will rust quickly if you don’t. Once dry, use a 100 or 120 grit flap disk to polish up the metal and smooth out any rough edges. Always wear rubber gloves and a respirator when working around muriatic acid. It’s dangerous stuff.
Prior to bolting on all the layers, you’ll want to seal the project using a metal sealer. The Rustoleum brand sealer was dry to the touch in a couple minutes. The sealer will darken the metal a bit.
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I did a little photo shoot/video on top of a mountain and had some fun. Love this torch!
This week’s project is one I’m very proud of and like no other I’ve ever created. A fellow podcaster and friend John Dumas owns a wildly successful company named EntrepreneuronFire.com which promotes entrepreneurship using a podcast. His podcast is getting over 500,000 downloads per month and is generating over 6 figures each month. Crazy huh??!! He’s even started a podcasting community called Podcaster’s Paradise to help others learn how to podcast and I’d highly recommend it. *Disclosure: Please note that some of the links placed in this article are affiliate links. This means you’ll be helping support more free DIY Projects and that my site will earn a commission if a sale takes place. Thanks for your support!
After the designs and letters are cut you’ll want to remove the slag. I typically use an angle grinder with a flap or grinding disk for this process. You can also chip away slag using a hammer and metal chisel.
Well, time to show this bad boy off! I put the artwork in the tractor and got a couple outdoor pics and some video footage.
I came up with an idea for the project and created it to scale in a program named Adobe Illustrator. The sign is 64 inches wide and the circle is 18 inches in diameter.
Hobart Flux Core 110 Volt Welder Hobart 250CI 110 Volt Plasma Cutter Dewalt Chopsaw Dewalt Angle Grinder 20 Volt Dewalt Angle Grinder (the battery powered version) – Super awesome tool!
I tack-welded bolts on the back of the circle and then screwed 2 inch long pieces of the threaded rod into each. The flame got a couple nuts welded to it too. In addition, I added a 1 1/4 inch wide piece of flat bar to hold a candle behind the metal flame. Side view of a candle resting on the metal bracket.
Seal the front and back of each piece. Adjust the bolts to allow proper spacing between layers. Then attach. This is the back side showing all items bolted onto the rear panel.
When it comes to decorating your walls at home, metal wall art might not be the first idea that pops into your mind. It’s all about expressing yourself through art in making your house a home. This article will explain how you will find a basic guideline in order to make your own metal wall art, along with some hints and tips.
Next, I cut 3/4 inch tubing to go around the perimeter of the back panel using a chopsaw.
Here is a photo of the sign hung. I used a cleat system to hang the sign which made it super simple to get on the wall.
Start experimenting with drawing random shapes and lines on pieces of paper. Don’t be afraid if you get it wrong the first few times. It takes time and practice. Once you’re sketches are done, consider the material that could be used. Ask yourself, what color the metal should be to suit the room best. Consider using warmer colors so that the art does not appear industrial and cold. If you are planning to make the art yourself, you must also think of the flexibility and softness of the metal. Keep in mind that you do not have the tools that a professional artist has, nor do you have the experience. Always be ready to ask for advice when you are buying the metal to be sure that it suited for your artwork.